Österreichische Staatsdruckerei

Precision work at Österreichische Staatsdruckerei thanks to Barcotec system

OeSD Group is one of Europe's leading providers of end-to-end identity management solutions. It develops and produces high-security documents such as the passport with chip and biometric security features. Not only does it handle orders from all over Austria, the OeSD Group also serves and supplies customers in more than 60 countries around the world.

Each magazine is taught once and thus assigned the respective data matrix code (Photo credit: Sabrina Auer/Österreichische Staatsdruckerei)

The 100% principle consistently applies to the production of the documents - it must be ensured that all finished passports have been produced completely and without errors. This high quality standard is rewarded with a high level of customer confidence.

Reducing errors or rejects is therefore a top priority: especially the finishing stage, where the printed semi-finished products are processed into finished booklets with bookbinding machines, represents a critical point in the manufacturing process.

It must be ensured that the right semi-finished product from the right country is inserted in the right position. Therefore, the Österreichische Staatsdruckerei has decided to handle these highly critical steps with an automated solution from Barcotec.

Österreichische Staatsdruckerei Employee with terminal

Deviations can be precisely localised and corrected via the Barcotec industrial terminal.

Up to nine magazines are loaded with printed sheets on one machine, with an alignment check implemented in the process with the Barcotec solution and equipment. An individual data matrix code is used to personalise each sheet. Before the start of the production job, each magazine is taught once and thus assigned to the respective data matrix code. The semi-finished product is read with a hand scanner and checked for correct material, correct position and printing passes.

If no code or not the expected one is read, this leads to an immediate stop of the machine. This is indicated with a precise localisation on an industrial terminal from BARCOTEC. This ensures that not a single book is incorrectly assembled, laminated or embossed - thus reducing waste to a minimum.

On another machine, the RF-ID chip is installed in the passport and this is glued to the cover. Here, too, scanners are used to check the alignment of the "passport interior" and RFID chips by means of QR (quick response, a DENSO invention) or data matrix code.

With BARCOTEC's scanners, all semi-finished products are checked with pinpoint accuracy and rejects are greatly reduced. (Photo credit: Sabrina Auer/Österreichische Staatsdruckerei)

The biggest challenge was to enable reading in the existing machines with a fixed installation space, with mobile components and an existing machine cycle. For this purpose, the scanners were installed in a non-critical position and the reading field of the camera was deflected. Damping and the angled position of the deflection mirrors prevent machine vibrations and paper dust from interfering with the inspection process. The reading cycle is taken from the machine's drive shaft. The time offset of the readings between the nine insert magazines was determined and adjusted in intensive cooperation with experts from the Barcotec company and the skilled workers of the ÖSD.

The staff quickly recognised the benefits of the new system and thus also accepted it positively. The application is described as user-friendly, stable and solid.

This pilot project was handled to our complete satisfaction. Barcotec proved to be a flexible, creative and reliable partner throughout the entire process.

Mag. Lackner, Managing Director/CFO of the OeSD