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Work Smarter, Not Harder, in the Bindery

February 16, 2012 By Michael Seidl, Print & Publishing magazine
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Thomas Krischke, commercial postpress manager at Heidelberger Druckmaschinen AG, believes that the dominant trend will be to drive to increased efficiency and productivity. In finishing, he explains, automation serves primarily to reduce makeready times for frequently changing small runs, the most extreme case being single-copy runs in digital printing. With large print runs, however, the productivity of the overall process is the key factor.

At Müller Martini, automation has always been a key focus of development. It says simpler, smarter operation results in faster makeready and error avoidance, and thus higher productivity.

“As print runs get smaller, workflow automation and the organization of the associated business processes, such as logistics, become even more important,” stresses CEO Bruno Müller.

“We haven’t reached the ceiling yet,” adds MBO Sales Manager Jan Oldenkott. “The next stage in finishing will be book-on-demand printing.” His vision is to produce every book with a different format.

Olaf Wallner, marketing, sales and service manager at Kugler-Womako, sees two key trends—a high level of automation in industrialized economies and fast format changes with small- to medium-sized batches. He points to productivity as the dominant force, particularly in mass production. The requirements, Wallner says, are for low staff levels and high productivity, which can only be achieved with a high degree of automation.

“In response to customer pressure, manufacturers have developed fully automatic machines,” says Kai Büntemeyer, CEO of Kolbus, “but these are not generally used to modernize traditional, manual production processes. Machine development has only reached a ceiling to the extent that the machines cannot be automated any further in themselves. There is still plenty of potential as far as machine users are concerned.”

At Swiss magazine and newspaper specialist Ferag, automatic makeready processes come as standard on its gatherer-stitcher drums thanks to the PreTronic presetting system. Where economically feasible, format changes are performed by precision servomotors at all the relevant positions.

“In the fight for newspaper contracts, low unit costs are essential. The demand for near parity of net and gross output takes priority,” explains Ferag CEO Jürg Möckli. But automation alone is not enough, he adds. Reaching productive speed quickly when changing from one job to the next is equally important.

For Horizon, automation is also the order of the day. Because the trend is towards increasingly small print runs, efforts in automation are focusing on machine setup, which needs to be both faster and simpler. If a machine has to process five or six different jobs in a day (which is not unusual nowadays), the difference between a highly trained operator taking 10 to 15 minutes to set it up and a semi-skilled person needing just 5 minutes to do the same job without paper waste is significant.

Robin Greenhalgh, Duplo International chairman, agrees. “Automation will develop further because more and more areas of the printing industry will have a need for it,” he says.

Greenhalgh cites new multifunctional finishing systems that allow more automation while delivering higher speeds as a prime example. They enable perforation in two directions for the efficient production of coupons, tickets and direct mailings, which until recently has been reserved for traditional processes such as offset printing.

Digital finishing: a growing segment
The increase in the number of digital production units has naturally increased the demand for high-performance finishing solutions. MBO has a wide range of solutions to offer, from unrolling, plough folding and cross-cutting (with the option of cutting to different lengths and even different chip-out lengths) to fully automated delivery systems for signatures, flyers and single sheets.

“We can separate different blocks from book-on-demand production by title and send them directly to the perfect binders. We can even handle different numbers of signatures per block,” notes Jan Oldenkott.

E.C.H. Will offers an integrated finishing solution for high-volume production of digitally printed books. The machine turns printed paper webs into blocks of individual sheets which can then be sent to the binding process. The system offers high productivity, reduced paper waste, complete format flexibility and minimum makeready times.

Müller Martini developed one of the first industrial integrated solutions for finishing digitally printed products, which has now been installed in saddlestitcher, perfect binder and hardcover production systems all over the world. But the company’s digital solutions are designed with more than just finishing in mind—they enable end-to-end integration of all processes, from prepress data to the finished product.

As far as Kai Büntemeyer is concerned, there is no such thing as digital finishing. The outcome of the finishing process, he argues, is always a physical product. There is, however, such a thing as finishing for digitally printed products.

Kolbus offers two solutions, EPCO and INDI. EPCO, or Electrophotographic and Consumer-published, involves the production of high-quality one-off products. INDI, or Industrial Digital Printing, refers to the fully automated production of products.

“For the past two years, EPCO has made up 25 percent of our sales. INDI is a large-scale experiment, but outperforms digital printing with a capacity of one million A4 pages an hour. We are waiting for printing machine manufacturers to catch us up,” says Büntemeyer.

Focus on green finishing
Ecology and sustainability are the subject of much interest, and not just in traditional printing. This trend is as relevant to the finishing sector as to the rest of the printing industry, and market players must respond accordingly, particularly as it is also becoming an important customer requirement. A finishing machine uses much less energy than a printing machine.

Nonetheless, at Heidelberg, minimizing energy consumption is still one of the primary development goals in finishing technology. Its saddlestitcher is equipped with a modular drive system that allows the individual modules to be shut down separately to save energy. During setup, only the required feeder is in operation and not the whole machine. Each hopper has its own servo drives, which stop automatically in the event of an error. Other machines only stop after two or three brochures, which then end up as waste. With an assumed annual throughput of 15 million 36-page A4 brochures, this saves 5 tons of paper a year.

Müller Martini set up its “Going green” program several years ago. “It’s important to us to convey this environmental commitment through our EcoBinder,” says Olaf Wallner.

This binding machine makes paper-bound ring binders that are 100 percent eco-friendly and recyclable. These are the first products to be manufactured solely from paper—a completely new market offering. The environmental footprint of an operational finishing system needs to be considered in the light of its actual productivity.

“The development of systems offering optimum net output is a highly effective way to reduce environmental footprint. This is something we are passionately committed to,” says Kai Büntemeyer.

Ferag AG has always believed in stringent environmental standards. The company uses only renewable energy sources, returns surplus heat to an energy recovery system, and demands maximum energy efficiency in all its operating processes. Engineers use simulation software to design and develop optimized components and systems, while the production systems use state-of-the-art motors and electric modules. Logically enough, this results in finishing processes which are as eco-friendly as possible.

What potential for innovation?
The word “innovation” is frequently overused. Is there in fact any potential left for innovation in the finishing sector? Horizon points out: “Innovation is defined as introducing new products, ideas or methods.”

Müller Martini provides several examples: the numerous quality control features now being integrated in finishing machines; full automation; the digital workflow system Connex with standardized platforms; and the wide range of digital solutions which have recently been developed. Then there are high-output machines for multishift production, which now offer more intuitive operation and a wider range of variants. There is also an inserting system, which is designed to cater for the individual needs of newspaper operations of all sizes.

So is there any potential left for innovation in finishing?

“It would be an interesting conversation topic for a business lunch,” says Büntemeyer. “You could take a spoon and discuss the need for innovation in this tried-and-tested utensil. That would be on a par with a book.”

Between the publisher and the consumer there are certainly complex processes concealing infinite potential for innovation, but these are almost entirely exploited by recombining ideas from other areas. “So in all honesty, we would propose modest use of the word ‘innovation’,” Büntemeyer concludes.

At Heidelberg, innovation is being driven by both technical development and application technology.  Its latest folder with pneumatic twin lay system is a perfect example of how an ingenious technical feature can achieve a significant gain in productivity.

“For me, the measure of an innovation is whether it offers a significantly enhanced benefit for our customers,” says Thomas Krischke.

The imperative at present is to develop the right applications for the new trends emerging in digital printing. In recent years we have seen an almost complete shift from film to digital cameras on the consumer market. For printers, this has meant new products such as photo books and personalized cards. Various new regulations are demanding modifications to packaging; safety requirements are becoming stricter, and in some cases Braille text is now mandatory. Future generations of web-fed and sheet-fed inkjet printers will also open up new business opportunities. All these developments will generate new requirements for the finishing industry.

“What inspires us is the fact that there are still plenty of paper-based developments to come that still need solutions,” says Robin Greenhalgh.

“We make a distinction between technological innovation and process innovation,” says Jürg Möckli.

The two are mutually dependent, and involve partnership between Ferag as a systems manufacturer and the customer. In addition to innovation for efficiency, aimed at minimizing unit costs in mass production, there is innovation in specific solutions for companies seeking to occupy a specialist niche. The customer’s specific needs are identified through an ongoing dialogue. One example of innovation at Ferag is the integrated finishing system with polybagging, gathering, stitching, trimming, inserting and bundling.

Drupa 2012: the industry benchmark

drupa is the showcase for the whole industry. Every four years, the print media industry comes together in Düsseldorf to set the pace for the next few years. Trying to find out months in advance of the event what new products will be on show is rather like consulting the Oracle of Delphi. But this didn’t stop us from asking.

Müller Martini will be presenting several new solutions covering its complete product portfolio, with a special focus on MMServices.

MBO will again be exhibiting in Hall 6 along with other finishing systems manufacturers.

MB Bäuerle plans to showcase its latest developments in automated folding and inserting solutions.

Kugler-Womako will present a machine that sets new standards in processes, end product quality and usability, and offers real innovation in this market segment with added value for the customer.

“Unfortunately, digital printing is currently proving a barrier to innovation in the industry,” says Büntemeyer. “Huge budgets are being blocked while people wait to see what future role digital printing will have.”  He believes that the printing technology industry will have to eliminate this obstacle at Drupa 2012.

Kolbus will be seeking to do this with its own presentations, but will also be showing completely conventional bookbinding machines at remarkably affordable prices.

For Horizon, the countdown to Drupa started ages ago. In 2012, the company intends to focus more on finishing technologies for digitally printed products than at the last Drupa.

Ferag intends to concentrate on process optimization for greater efficiency and substantial reductions in unit costs, innovative control concepts, and new added-value solutions.

It is certainly set to be an exciting roll on 2012.


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