Why Blind Spots can cost you a lot of money: 100% Quality Assurance for RFID Labels

The BST TubeScan digital strobe is designed for inline visual inspection in label converting processes. Using high-resolution camera technology and intelligent image processing, it enables 100% inspection at production speed—detecting print defects, verifying variable data, and checking the presence and position of RFID inlays.

With its compact design, flexible integration, and advanced illumination technology, TubeScan delivers stable and reliable inspection results across a wide range of label materials.

In the following interview, Roberto Maiocchi, Industry Director for Labels and Narrow Web at BST, explains how combining visual inspection with RFID functional testing helps eliminate quality blind spots and improves production efficiency.

Question: RFID converters can struggle with undetected defects in RFID labels—issues that only become visible at the customer site, leading to complaints, waste, and costly recalls. How can manufacturers gain control over quality?

Roberto Maiocchi: That’s exactly the challenge we are addressing. RFID labels are hybrid products—they combine print quality with electronic functionality. If you only inspect one aspect, you risk missing critical defects. Our approach is to enable 100% quality assurance across both dimensions, so every single tag is verified before it leaves production. This significantly reduces complaints, increases yield, and provides full transparency.

Question: So the problem is, that traditional inspection systems don’t capture the full picture?

Roberto Maiocchi: Exactly. Many systems focus either on visual inspection or on RFID functionality—but not both in an integrated way. This gap creates blind spots in production. With our TubeScan system combined with Voyantic’s Tagsurance 3, we close that gap and provide a fully integrated QA solution.

Question: How does this combined solution work in practice?

Roberto Maiocchi: We combine two best-in-class technologies. BST TubeScan performs 100% visual inspection—checking print image quality, verifying variable data like QR codes, and inspecting the presence and positioning of RFID inlays. Tagsurance 3 is responsible for the functional side. It measures the RF performance of each tag, encodes the data, and verifies that the encoding is correct. This includes checking EPC data and ensuring that the tag responds as expected. The result is a synchronized system that evaluates both the visible and invisible aspects of each label.

Question: What does a typical digital workflow look like?

Roberto Maiocchi: The process starts with data generation—usually from a database or ERP system. During production, TubeScan checks the printed data, while Tagsurance encodes and verifies the RFID data in parallel. All results are recorded per label. At the end, the operator receives a combined roll report that includes both visual and functional inspection results. This creates full traceability across the entire production run.

Question: What do I use the roll report for?

Roberto Maiocchi: The roll report enables you to identify and remove defective labels during doctoring. Operators can immediately identify defective labels and know exactly why they failed—whether it’s a print issue, an inlay problem, or an encoding error. More importantly, it provides full documentation for every single tag. That level of traceability is becoming increasingly important for brand owners and regulatory requirements.

Question: How does TubeScan work in detail?

Roberto Maiocchi: TubeScan is a high-performance inspection system designed for inline use in label production. It uses advanced camera technology and intelligent image processing to inspect every label at production speed. It detects print defects, verifies codes, and checks the position and presence of inlays. The system is highly adaptable and can handle complex layouts—even with multiple labels per repeat.

Question: What makes TubeScan stand out?

Roberto Maiocchi: TubeScan is a proven and leading technology in the market. What makes it unique is its reliable defect detection software with high resolution and its compact design.

With just 125 mm in the web direction, it fits easily into virtually any converting machine.

The inspection algorithms ensure stable and reliable system performance, while giving operators full control over the types of defects they want to detect.

The “Multiplex Illumination” concept is designed to use multiple illumination sources simultaneously allowing inspection of challenging substrates such as clear labels and specific label features like invisible or luminescent inks, braille, or back printing. All of this comes at a very attractive price point.

And another aspect that should not be overlooked: We understand that downtime is critical in production. Even in the unlikely event of an issue—whether technical or application-related—customers benefit from fast response times from our service team and direct access to our hotline. We don’t just deliver systems—we provide ongoing support to keep your production running smoothly.

Question: What are the main advantages that BST can offer its customers in terms of support and assistance?

Roberto Maiocchi: BST provides a highly structured and effective support model, based on a global presence integrated with a centralized help desk service, complemented by local expertise and on-the-ground support. This approach ensures fast response times, consistency in service delivery, and a deep understanding of each customer’s specific needs.

In line with the “Enable 2028” strategy of the Elexis Group, BST places the customer at the center of all its activities, delivering a proactive, continuous, and value-driven service. The combination of a worldwide structure and local support enables BST to balance high standards with tailored solutions, offering a comprehensive, reliable, and customer-centric support experience.

Question: What about my return on investment?

Roberto Maiocchi: The benefits are very clear: higher yield, less waste, and significantly lower complaint rates. At the same time, converters can offer their customers verified quality on a per-tag basis. Customers want proof, not assumptions.

Integrated inspection—combining visual and functional testing—is the only way to deliver that reliably.

That builds trust and creates a real competitive advantage. Over time, the data also helps to optimize the process and eliminate recurring defects.

About BST

BST GmbH, an elexis Group company, is one of the leading suppliers of quality assurance systems for web processing industries. The Bielefeld-based company offers solutions for web guiding, surface inspection, web monitoring, 100% inspection, color measurement, color management, register control and automation. The company has decades of practical expertise in these areas, with installations at more than 15,000 customers worldwide in the printing and packaging, paper and film, rubber and tire, battery and fuel cell, and printed and organic electronics industries. BST stands for high-quality quality monitoring, smooth production processes and first-class service worldwide.

www.bst.elexis.group