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Sensors for Precise Measuring Tasks in Photo Book Machines

Weddings, children, family, celebrations, travel, animals, recipes – there are countless occasions and events that people like to capture in photo books. The machines on which they are produced are, in many cases, made by the Swiss company Imaging Solutions. For the demanding detection and measuring tasks involved in the automated production of books, this world-leading supplier of solutions for the image post-processing industry trusts in the OD200 laser distance sensor from SICK.

Photos, snapshots and text in a custom layout, professionally printed and finished in high quality – with photo books, these joyous moments and happy memories are quickly at hand at any time. Based on regional sales figures, experts estimate that around 60 to 70 million photo books are produced per annum worldwide. About one third of that is in Europe – and a significant proportion of that is produced on machines from Imaging Solutions. "This is because our company began specializing in modular systems for the automated production of layflat photo books and other high quality print-on-demand products back in 2003," explains Chiara Bianchi, who is responsible for marketing & video production at Imaging Solutions. "Specialists around the globe in the photo, print and graphics industry value us as a competent partner and supplier of innovative printing finishing technologies."

Sensors support automated print processing

The automated workflow systems from Imaging Solutions enable high-quality and at the same time efficient print processing of books, photo books, photo calendars, postcards and posters as one-offs or in small runs. "The suppliers of photo books and other customers in the image post-processing industry trust in the fault- and downtime-free processes in our photo book machines – from single-sheet processing to sorting and feeding processes right through to book binding," explains Patrick Häni CPO, the person responsible for all production at Imaging Solutions. " Everywhere where sensors are used in the machines, we have been trusting for many years in the expertise and products from SICK. The latest example is the OD200 laser distance sensor, which is used in a variety of demanding applications."

The challenge: glossy paper and dark prints

Many people who design their photo book on the Internet and then order photo services and printing from online suppliers decide for glossy photo paper – in particular because the photographic subjects achieve their maximum color effect, depth and brilliance on them. Gloss also poses a challenge for the automation of photo book machines, in particular where maximum precision is required – specifically, in the case of Imaging Solutions, when detecting and measuring glossy photo paper with a thickness of just 130 µm. "Gloss means mirroring and random reflections, which poses problems for many optical sensors," explains Michael Kiss, Strategic Product Manager at SICK AG. "Dark prints can also be challenging, however, due to the inadequate reflection." Thanks to the OD200, he was able to offer Patrick Häni and Imaging Solutions a reliable solution for both scenarios.

Reliable measurement and detection even on glossy photo paper

The OD200 is a compact laser distance sensor for measuring short ranges that has enriched SICK's portfolio of displacement sensors since mid-2025. With its newly developed measurement core with high-resolution receiver unit and optimized optical system, the OD200 miniature distance sensor achieves a level of precision, linearity and repeatability that is normally reserved for high-end devices. The sensor thereby ensures a high measurement stability and a reproducible detection and switching behavior. "And this is also the case for glossy surfaces," says a very pleased Patrick Häni.

In the sheet separation unit where the photo paper is inserted as a stack and then individually separated and processed, a sensor continuously measures the height of the stack while another OD200 ensures that there is still paper present in the stack. By measuring the distance to the top sheet, the stack can be raised to the correct height to enable the vacuum suction unit to reliably draw off a sheet," says Patrick Häni when describing the tasks of the laser distance sensors. "Thanks to the performance of the two OD200s, smooth feeding of the paper is ensured at all times." In a further application within the machine, OD200s are employed to draw in card stock for inserts and back covers as well as for the detection, position determination and height checking of bound books in the discharge unit.

Laser distance sensors

More productivity through simple and reliable distance measurement

OD200

Collaboration as an important element for further development

Imaging Solutions and SICK have been collaborating trustfully and successfully for many years. New approaches and opportunities for further improving quality assurance and process control are discussed and evaluated on a regular basis. "This exchange, in which we can count on the reliable advice, high quality standards and innovativeness of SICK, is an important element in the further development of our technology," confirms Patrick Häni. "Specific requirements are quickly identified and tailored solutions promptly developed. This and the easy integration of sensor solutions such as the OD200 into our existing systems have sustainably optimized our processes and further strengthened our trust in SICK as a strategic technology partner."

It is hardly surprising, then, that they are already jointly pursuing further ideas such as the integration of intelligent camera systems so the complex workflows and processes in the machine can be analyzed in a targeted manner with the help of high-resolution and fast image captures.