Morgana’s ‘Flying Knife’ Folding Technology Does Away with Buckle Plates, Conventional Knives

Morgana DigiFold 5000P folder/creaser.

When you hear the term “flying knife” generally the first instinct is to duck. However, in this instance, flying knives are a very good thing.

Morgana’s DigiFold 5000P folder/creaser uses its patented “flying knife’ folding system. This exciting technique dispenses entirely with buckle plates and conventional knives, using instead an electronically controlled, contoured flying knife around extra large diameter rollers. This knife moves at the same speed as the material passing through the machine to create a fast, accurate fold.

Complementing this innovative technique is another patented device called a dynamic sheet deflector. Rather than the solid deflector used in most folders, the dynamic sheet deflector only comes in contact with the leading edge of the sheet. This allows single or multiple folds to be performed without risk of scratching or marking at over 5,000 letter-size sheets per hour, which makes it extremely useful for (but not limited to) digital print.

As a matter of fact, the 5000P was developed as a mobile finishing center—one that is equally effective with digital output or heavy cross-grained stocks printed by conventional means and laminated stocks. “It’s all about speed,” states Colin Harding, Production Director for Face Creative, London. “We have to finish output from two five-color Xeikon and two six-color HP Indigo presses, consisting of short runs and a variety of different types of work, which means that we need to be both fast and flexible.”

The 5000P also incorporates Morgana’s patented automated creasing technology, DynaCrease. Perforation is now standard, with up to five perforation wheels, and a newly-designed feeder is powered by a more powerful pump that allows greater airflow efficiency and a higher pile to be loaded. The machine can accommodate up to a 28×15˝ sheet size, and up to 120-lb cover stock. It’s JDF ready, with fully automated job set up and intuitive programming capabilities.

Trish Witkowski is Chief Folding Fanatic at, and president of Rock the Mailbox. An educator, author, speaker and award-winning designer, Trish has a specialized expertise in creative solutions for direct mail and marketing, and is the curator of the world's most exciting collection of folded print and direct mail samples. Trish is the creator of the FOLDRite folding template system, and has authored many resources, most recently Direct Mail Simplified, and Paper Folding Templates for Print Design. She also hosts a popular weekly e-video series "60-second Super-cool FOLD of the WEEK", and is an instructor at Trish holds a MS in Printing and a BFA in Graphic Design from RIT.
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