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Our staff at Gulliver Factory stringently implement quality control to make sure all products are inspected.
As a DM specialist company, we implement quality control by painstakingly automating line processes to ensure total inspections.
Hence, we implement mechanical inspections for all processes to achieve surefire quality control in order to deliver directly clients’ DMs to their customers.
Offset printing
Our star performers are the H-UV (hybrid UV) printers, which offer rapid drying, so that as soon as printing finishes, the next process can begin, enabling us to meet tight deadlines.
Also, with in-line high-precision cameras, all printed matter is inspected - no tone slip, dust or pinhole escapes the camera’s eagle eye. Furthermore, our QR code and 2D barcode setup uses automatic collators to collate data to achieve a rigorously high level of quality control.
KOMORI LITHRONE GX840RP
Kiku-zenban (636 x 939mm paper size) H-UV8 color printer
KOMORI LITHRONE S29
Kikuhansai (469 x636mm paper size) H-UV6 color printer (with varnish coater))
This can carry out stable duplex printing with paper weights from 27kg (specialist thin-paper printing) to 350kg (thick paper), at a maximum speed of 16,500 rpm/hr, using a simultaneous all-color printing plate switching device to maintain high productivity. With this printer, we can surface process in line to print UV embossed mail (one of our original products) at a maximum speed of 16,000 rpm/hr, which truly is high-speed printing.
Total inspection
High-precision camera inspects all products as they pass through the indicated slit
Our star performer printers maintain quality control using in-line high-precision cameras to ensure total inspection. These cameras automatically check even the smallest of problems, including color issues, color consistency and pinholes. What is more, we maintain in-line created records and logs.
2D barcode collator
Scans printed items Checks 2D barcode Also inspects URLs
As the paper world fuses with the IT (web) world, more and more printouts carry 2D barcodes, such as QR codes. Indeed, smartphone cameras are now commonly used to read 2D barcodes, making the demand for such codes ever greater. Accordingly, our star-performer printers carry 2D barcode collators to automatically check URLs to prevent access errors due to poor printing. In addition to being installed in the 636 x 939mm paper size H-UV8, our 460 x 636mm paper size H-UV6 is the only printer of its kind in Japan to be equipped with such a collator system.
H-UV (hybrid UV) printing merits
Meets tight deadlines
Rapid drying means there is no waiting, so the next process (after printing) can be carried out immediately to meet tight deadlines.
Durability
The ink film is incredibly strong, mitigating smudging during postal delivery.
Environment
H-UV Co2 emissions are approximately one quarter of those of conventional UV printing, making the H-UV more environmentally friendly.
Digital printing
Kodak Prosper DH6240  high-speed inkjet printer
  High-precision cameras Printing heads
This printer mainly carries out variable printing on direct mail.
Note that not only is this printer equipped with two print heads but it also can variably print differing customer data, QR code and other such things on each sheet of paper.
And, after printing, high-precision cameras check the printed content on every sheet, to ensure quality.
What is more, an image log of all printouts is kept.
Fuji Xerox
Color 1000 Press
Fuji Xerox
Nuvera 314 EA
Printing out at a speed of 80 sheets per minute for A4 size, this press offers variable printing at a high resolution approaching that of offset printing. With this printer, we can offer clients monochrome on-demand (small lot) printing as well as hybrid variable overprinting on products that have already undergone offset color printing.
Hybrid printing
This is a blend (hybrid) of offset printing and digital printing, where printed matter (offset) gets overprinted with variable data in multiple locations by the Nuvera Prosper printer. Hybrid printing is great for one-to-one marketing.
Quality control of direct mail
Automatic printout inspection machine (Kensatto II) Folding and crimping (bonding) processes
The plate checking here involves high-precision cameras (9 MP CCD) collating two printout sheets or two pieces of data at a time to prevent irregularities. To fold and crimp our unique direct mail, we use specially customized equipment to produce products of stable quality.
Automatic glue injectors In-line inspection system
We use automatic glue injectors to complete the “peel-and-view” crimp finish on DMs. Poor crimping never escapes as this system halts whenever a crimping irregularity occurs to ensure good quality. Even on our enveloping process line we have CCD cameras and weight sensors to inspect all enveloped materials.
Variable printing Inspecting
Variable printing lets us vary the content for each sheet - in other words, we can produce individual tailormade DMs to directly target individual consumers. After the name & address is printed, quality control steps in to strictly inspect DM quality using CCD cameras, light transmission sensors and thickness sensors.
Sorting Cutter (POLAR P115-PF)
After the inspections, postal code classification (sorting) work takes place, with an automatic sorter used to accurately sort the DMs. This high-speed cutter is highly accurate and operable, while knife is also easy to replace safely.
What is more, this cutter automatically stacks cut printed items onto a pallet to be transferred to the next process, which is a tremendous piece of labor saving.
Pest control Security
We use insect repellent nets and fluorescent lights to prevent insects entering work areas and interfering with products. We maintain a strict checking system - from receiving/forwarding data through to in-house data processing, printing and post-print processes - to thoroughly ensure the confidentiality of corporate and private information.
Quality control for each process

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