Nikon’s advanced iNEXIV VMA-2520 video measuring system transforms quality control at Greek manufacturing leader Kalfoplast SA, delivering unprecedented precision and efficiency in plastic component inspection whilst cutting measurement times by up to two-thirds compared with traditional methods.
Nikon’s latest metrology innovation, the iNEXIV VMA-2520 video measuring system, has revolutionised quality control at Greek manufacturer Kalfoplast SA. The precision measurement solution enables the company to meet demanding production targets whilst maintaining the exacting standards its customers require.
Founded in 1989 and based in Thessaloniki, Kalfoplast has built a reputation for innovation in mould manufacturing and plastic component production. The company’s comprehensive end-to-end solutions, from design through to manufacturing, have made it a trusted partner for international construction firms.
The implementation was facilitated by QControl, Nikon’s Greek partner. Originally part of D.BREKOSIS, QControl specialises in dimensional measurement solutions and industrial metrology. The company expanded its capabilities significantly after 2007 when Theodoros Tsagaris and Sakis Giannelis joined the team.
Kalfoplast’s state-of-the-art facility houses 28 injection machines alongside a complete machine shop equipped with CAD/CAM systems and rapid prototyping capabilities. The plant can produce plastic components weighing up to 4kg. Seeking to enhance its measurement precision for both moulds and finished parts, the company identified Nikon’s video measuring system as the ideal solution for its next phase of technological advancement.
The challenges of expanded production
As production volumes grew, Kalfoplast faced increasing challenges with its measurement systems. Complex plastic components, with their intricate microstructures and fine details, demanded both speed and precision in quality control. Traditional contact-based coordinate measuring machines (CMMs) were proving inadequate, with their slow processing times and risk of damaging delicate plastic surfaces.
The company’s modern injection moulding processes required a more sophisticated approach. The solution came through collaboration with QControl, Nikon’s Greek partner, who recommended the iNEXIV VMA video measuring system. This non-contact optical system offers high-speed measurement capabilities alongside unprecedented accuracy. Its multisensory technology combines video and laser, enabling precise 3D analysis of even the most intricate components.
Nikon’s iNEXIV VMA key features and benefits include:
- X, Y, Z accuracy up to 2μm.
- Automated measurements of multiple parts at the highest speed in the industry.
- Built-in laser for measuring and copying the height profile in Z, with an accuracy of 3μm.
- 126x magnification, large 50mm depth of focus and perimeter LED lighting for detailed measurements.
- Advanced AutoMeasure software with CAD-to-Part comparison, offline programming and shape analysis.
For Kalfoplast, the iNEXIV system‘s key advantage is its remarkable speed compared to traditional CMM contact methods while maintaining precision in measuring complex dimensions and geometric tolerances. The system’s advanced optical capabilities are particularly suited to Kalfoplast’s products, whose soft surfaces and intricate microstructures demand sophisticated lighting and identification tools.
Integration into Kalfoplast’s production workflow proved seamless. The intuitive AutoMeasure software allowed technicians to quickly incorporate the system into existing quality control processes, supported by QControl’s certified specialists who provided comprehensive installation, training and ongoing support.
The results have been transformative. The system’s automated, non-contact measurements eliminate surface damage risks whilst delivering unmatched repeatability across all materials. This enhanced speed and precision have enabled Kalfoplast to meet current demands whilst building capacity for future growth.
The investment has strengthened Kalfoplast’s position in the European market as an innovative, quality-focused manufacturer. By adopting Nikon’s cutting-edge metrology solution, the company has not only upgraded its measurement capabilities but also secured its competitive edge in precision mould and plastic component manufacturing. Through its partnership with Nikon and QControl, Kalfoplast is now ideally positioned to meet the evolving demands of global manufacturing.
