postpress_overview

Heidelberger Druckmaschinen AG

Postpress Overview

Postpress Overview – Trends and Technologies

Febr. 2007

Market Focus Finishing – Trends, News and Opportunities • • •

Printing begins with finishing It is the final product that determines the overall process Before works begins at the prepress stage it must be clear what the finished product is supposed to look like

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Postpress Overview – Trends and Technologies

Febr. 2007

Market Trends and derived development targets

Smaller runs

Shorter order lead time

Specialization and differentiation

Development targets

Operating simplification

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“Intelligent” automation

Modularity of the machine platform

Postpress Overview – Trends and Technologies

Febr. 2007

The demands in postpress are continuously rising due to changing basic conditions Bookbinders

Printshops

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Higher product quality Workflow integration Added value of the optional devices Price pressure due to overcapacity Shorter job processing times More jobs with lower print runs Product specializing / Differentiation

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More automation Workflow integration In-house postpress department Rate of utilization under 50% Shorter job processing times More jobs with lower print runs Lack of operator qualification

Postpress Overview – Trends and Technologies

Febr. 2007

Postpress jobs are not all alike Bookbinders: books, brochures, leaflets, mailings, calendars, forms, posters etc.

Printing

Printed web

Postpress

process

Printed sheet

process

General paper processing: technical documents, paper toiletries, decoration material, office supplies, toys etc.

Packaging material manufacturers: boxes, bags, tins, labels, envelopes etc.

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Postpress Overview – Trends and Technologies

Febr. 2007

Postpress – the ordinary madness

Job acceptance

Planed schedule

Prepress

Delivery deadline

Press

Actual schedule

Troubles:

Corrections f. editor

Paper quality

delayed OK for the print

Printing plate problems

Data handling

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Drying times

Post Press

Postpress Overview – Trends and Technologies

Which postpress processes are required to manufacture the following products?

1.

Map

2.

Newspaper

3.

Writing pad

4.

Single-layer brochure

5.

Multi-layer brochure (soft cover)

6.

Book (hard cover)

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Febr. 2007

Postpress Overview – Trends and Technologies

Map

1.

Paper cutting

2.

Folding

3.

Packaging

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Febr. 2007

Postpress Overview – Trends and Technologies

Multi-layer brochure (soft cover) 1.

Paper cutting

2.

Cutting the cover to size

3.

Finishing the cover (e.g.laminating)

4.

Folding

5.

Thread-sealing

6.

Collating

7.

Block binding

8.

Trimming

9.

Packaging

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Folding techniques

Knife folding technique

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Buckle folding technique

Postpress Overview – Trends and Technologies

Febr. 2007

With the buckle-fold technique, several folds can be made in a single folding unit.

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3 counter-rotating folding rollers • Buckle plate with an adjustable sheet stop • Non-cyclic, continuous production

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Postpress Overview – Trends and Technologies

Febr. 2007

The knife fold technique is always combined with the buckle fold technique • • •

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2 counter-rotating folding rollers Electronic knife monitoring system Adjustable sheet stop Adjustable side stops Rate-dependent, so the sheet distance is very important

A combination folder combines both folding techniques: buckle fold and knife fold technique

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Postpress Overview – Trends and Technologies

Febr. 2007

Increase Flexibility and Add Value by upgrading of Folded Products

Gate Folds

Gluing

0.5 – 1.0 mm

Perforating/Slitting L1

L1 L2

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L2

Postpress Overview – Trends and Technologies

Febr. 2007

Heidelberg folders are manufactured in Ludwigsburg (Germany), and they add up to a broad range of products

Stahlfolder KH-56

Ti 36

Ti 40

Stahlfolder TH-56 Ti 52

TD 112 Topline Š Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Febr. 2007

Stahlfolder KH

Delivery • Stream delivery (SAK) with pressing station (SPH) • Vertical stack delivery (VSA) • Horizontal stack delivery © Heidelberger Druckmaschinen AG

Folding unit • Parallel folding unit • Cross fold folding unit

Feeder • Flat pile feeder • Pallet feeder • Round continious feeder

Postpress Overview – Trends and Technologies

Febr. 2007

The product situation, job volume and available space are important when selecting the right type of folder Buckle plate folder

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Flexibility, due to modular design Large variety of folding techniques Multi-up works production Double-stream production is possible Good accessibility High folding capacity No cycles

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Combination folder

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Relatively low space requirements • Quick set-up • Advantages when printing on thin types of paper and double-volume book printing paper • Fixed folding layout

Postpress Overview – Trends and Technologies

Febr. 2007

Bolder Folders – The future of folding is right here in the TH/KH folders Heidelberg has taken the most robust folder series in the market and made it user friendly and productive • Available with a range of feeder and delivery options as well as thread sealing mailer components •

Stahlfolder KH Series of combination folders which feature a cross-fold module

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Postpress Overview – Trends and Technologies

Febr. 2007

In the format 70 x 100 cm, the TH/KH line allows for productive industrial folding

KH 66/78, professional folding of signatures

TH 66/82 stands for productivity •

• Productive

folding of 8, 16 and 32-page signatures • Electronic settings, production monitoring and checking • Low space requirements © Heidelberger Druckmaschinen AG

Electronic settings, production monitoring and checking • Perfect accessibility • Modular design • Numerous additional applications

Postpress Overview – Trends and Technologies

Febr. 2007

Operating simplification

Modular control MCT

Tremat

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Combination buckle plates

Liftkit for slitter shafts

Cross fold unit

“Extra-grip” folding rollers

Postpress Overview – Trends and Technologies

Febr. 2007

“Intelligent” automation

Touch Screen operation

Sidelays with target/actual-display

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New motorized combination buckle plates

Automated folding roller adjustment

Sheet ejection system

Airstreamtable

Postpress Overview – Trends and Technologies

Febr. 2007

Modularity of the machine platform

Slitter shafts can be retrofitted

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Gluing device

Gatefold attachment

Postpress Overview – Trends and Technologies

Folding rollers “Extra-Grip”

Operating simplification • Transport of sheets and creation of the fold • New steel – PU-grid: Overlapping of PU rings (no contact between steel bodies) • 10% more PU rings compared to previous folding rollers (PU share – steel share)

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Febr. 2007

Postpress Overview – Trends and Technologies

Control concept MCT with touch screen

“Intelligent” automation • 5 possibilities of machine adjustment: … conventional … step-by-step … integrated Compufold … workflow … foldtype catalogue

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Febr. 2007

Postpress Overview – Trends and Technologies

Motorized combination buckle plates

“Intelligent” automation • Motorized angle adjustment • Automated parallelism of sheet stops in deflector position or by starting a new job • Control supported sheet length compensation at angle adjustment of sheet stops

© Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Automated folding roller adjustment

“Intelligent” automation • Automated distance adjustment of folding rollers by drives and spindles • Measuring of paper thickness by a sensor on the feeder • Automated parallelism of folding rollers by starting a new job • Adjustment of one individual folding roller gap

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Febr. 2007

Postpress Overview – Trends and Technologies

Sheet ejection system

“Intelligent” automation • Double sheets, blank sheets and wrong sheets will be ejected before 1st station • Detection by... ... ultrasonic sensor ... blank sheet inspector ... image inspector • Available with and without frontmounted slitter shafts

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Airstreamtable „Intelligent“ automation • Transport belt transports the folded sheets from feeder to 1st folding station • Suction fan creates an airstream which streams through the transport belt vertical to the running direction • Vacuum air and airstream create a negative pressure and suck the sheet onto the transport belt of the Aistreamtable

© Heidelberger Druckmaschinen AG

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Intensity of air flow and thus negative pressure can be regulated Prism sidelay for exact sheet alignment

Postpress Overview – Trends and Technologies

Febr. 2007

Deliveries – Stahlfolder Speedbander SFA-603

The High-Speed pack delivery Stahlfolder Speedbander SFA can keep pace with any saddle-stitcher or folder: Excellent productivity and performance based on technically advanced solutions.

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Postpress Overview – Trends and Technologies

Speedbander – Customer Benefits

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High machine-tool efficiency: 600 packs per up, max. 4 ups Ergonomic working height Simple operation Short make-ready times Packs are perfectly stacked Straightforward changeover of sleeve-wrapping reels

© Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Deliveries – Twin Stacker TSH-50, 70, 100

The Twin Stacker TSH is a vertical stacking unit, which makes the delivering of difficult papers possible without any markings.

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Postpress Overview – Trends and Technologies

Twin Stacker – Main Features

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Rejection of mis-fed sheets and inspection sheet removal New height adjustable delivery table, the upper infeed table can be easily adjusted according to product thickness Staggering device standard Integrated pressing unit with two pairs of pressing rollers MTC Modular control technology

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Febr. 2007

Postpress Overview – Trends and Technologies

Twin Stacker – Customer Benefits

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Mark-free products due to new active principle (belt guide and pile formation) Higher ease of use by taking away of counted and separated products (pile formation) Delivery of single sheets and shingle stream possible Little work space and footprint Swivel-mounted operator station

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Deliveries – Stream Delivery SPH

The transport belts of the Stream Delivery SPH with pressing device take up the sheets coming from the folder or saddle stitcher and lead them through a pair of pressing rollers. © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

SPH – Customer Benefits

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Large displacement allows for ergonomic favorable removal height even with deep infeed from the folding machine Control panel always remains in ergonomically favorable position independent from removal height Good accessibility to the single stream table at the operator side (no switch cabinet)

© Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Folders in the large format field (> 72 x 102 cm) are mainly used for signature production with double stream

TD 94/ KD 94 Signatures

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TD 112 / 142 • Double-stream production • Map production • Signatures

Postpress Overview – Trends and Technologies

Febr. 2007

Trends, News and Opportunities in Postpress Direct Mail

Hot Gluing

Timed perforating and cutting Cold Gluing

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Postpress Overview – Trends and Technologies

Febr. 2007

Direct mail with leaflet and reply card Closed:

1 x opened:

Completely opened: WA-gumming

Reply card with selfaddressed envelope Š Heidelberger Druckmaschinen AG

6 cpl. pages for your advertisng message

Postpress Overview – Trends and Technologies

Febr. 2007

Double gatefold with reply card 1 x opened: Closed:

2 x opened:

Doubled reply card

Completely opened:

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Fields for your advertising message

Postpress Overview – Trends and Technologies

Febr. 2007

Mailing systems: from the printed sheet to the final mailing

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Postpress Overview – Trends and Technologies

Febr. 2007

Thread-sealing – time-saving, due to inline production

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Inline production (with no additional staff required) Low production costs (adhesive binding) High durability (thread-stitching) Good lay flat performance Ideal for textbooks, reference books, catalogues, calendars

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Postpress Overview – Trends and Technologies

Febr. 2007

Thread-sewing is the most durable binding method – the signatures are additionally connected by the thread Inside thread Back fold

Sewing needle Thread mover Hook-shaped needle Sewing needle Hook-shaped needle Thread mover Piercing needles (for holes in the back fold)

Piercing needles Hook-shaped needle Sewing needle Sewing needle Hook-shaped needle

Thread mover

Piercing needles

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Thread mover

Piercing needles

Postpress Overview – Trends and Technologies

Febr. 2007

Thread-sealing technique

Thread clamp

Folded sheet

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Puncture needle

Laydown and sealing tool

Pressure element

Postpress Overview – Trends and Technologies

Thread-sealing – Inline production

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Febr. 2007

Postpress Overview – Trends and Technologies

Adhesive binding

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Eurobind 500 1-clamp professional perfect binding machines for single sheet and signature / folded section applications

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Postpress Overview – Trends and Technologies

Febr. 2007

Eurobind 500 1-clamp professional perfect binding machines for single sheet and signature / folded section applications

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Postpress Overview – Trends and Technologies

Febr. 2007

HEIDELBERG EUROBIND 1200 SERIES 4-clamp perfect binding machine for single sheet and signature/folded section application equipped with: - central operation panel including pre-heating timer - pneumatically opening/closing of clamps for manual block inserting

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Postpress Overview – Trends and Technologies

Febr. 2007

Adhesive binding (perfect binding) Aligning and pressing station

Cover feeder

Dryer

Warming station

Delivery

Back-stripping unit (Lining station) Side gluing station 2nd gluing station Block infeed

Infrared intermediate drying Main gluing station Spine processing Feeder Jogging

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Postpress Overview – Trends and Technologies

Febr. 2007

The Heidelberg Eurobind 4000 System •

IPEX 2006 was the official launch of the sytem

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Postpress Overview – Trends and Technologies

First Public Trade-Show Presentation of Eurobind 4000

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Febr. 2007

Postpress Overview – Trends and Technologies

First Public Trade-Show Presentation of Eurobind 4000

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Prior to block binding, the folded sheets must be collated

Signature 1 ...

Collating

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Inserting

Postpress Overview – Trends and Technologies

Febr. 2007

Wire back-stitching is a fast, easy and reliable binding method for products up to 12mm

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Postpress Overview – Trends and Technologies

Febr. 2007

ST 100 – the specialist in the A4 range

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With up to 9000 cycles/hour, suitable for small to medium-sized print runs (up to 50000 copies) Product format (trimmed) from CD booklet format to A4 oversize Up to 10 mm stock thickness Up to four twin vertical feeders (= 8 feeders) Mark-free cutting, due to fixed belts Two-up production possible Short set-up times, due to menu-guided tool-free conversion Compact and space-saving

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Postpress Overview – Trends and Technologies

Febr. 2007

ST 350 – flexibility that guarantees profitability

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With up to 12000 cycles/hour, suitable for medium-sized print runs (50000 to 150000 copies) Range of applications: 10 to 20 million stitchings per year in one or two-shifts Product format from CD booklet format to A3 oversize Up to 12 mm product thickness Up to 16 feeders, including cover folder feeder in an ergonomically suitable height, with tilting feeder heads Various types of feeders (vertical, horizontal); Mark-free cutting

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Postpress Overview – Trends and Technologies

Febr. 2007

ST 450 – the gatherer-stitcher with the revolutionary concept allows for high flexibility

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Up to 16 mobile feeders (vert., horiz.) can be used on both sides of the chain Further shortening of the set-up times, thanks to automatic presetting of all aggregates. Ideal for frequent job changes. Servo-motor technology.

With up to 14000 cycles/hour, suitable for medium-sized to large print runs Product format from CD format to A3 oversize Mark-free cutting; Triple cut option. Up to 12 mm stock thickness CIP 3/CIP 4 interface and provisions for selective binding © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Febr. 2007

Commitment to the Folding Carton Industry

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Postpress Overview – Trends and Technologies

Prepress Artpro Barco

Press

Febr. 2007

Fold & glue

Die cut

CD-Speedmaster Varimatrix/Dymatrix Heidelberg

M-Gladbach

ECO/Diana M-Gladbach

Prinect

Diana Folder Gluer Dymatrix Die Cutter © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Process to produce folding boxes

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Product Portfolio Mönchengladbach Die Cutter Varimatrix 105 CS Dymatrix 105 CS Dymatrix 106 CS/CSB Dymatrix 113 CS/CSB Dymatrix 142 CSB

Folder Gluer ECO 80 ECO 105 Diana 45 Diana Pro 74/94/114 Diana X 115/135 Diana 145/165

Dymatrix 106/113 CS/CSB

Diana Pro 74/94/114

Jagfeed Japack Pro FAS 480 Diana X 115/135 © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Febr. 2007

Scope of material for die cutter

80 gsm

• Paper from 80 gsm • Solid board up to 1,400 / 2,000 gsm • Corrugated board up to 4 mm • Special materials such as aluminium or plastic © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Varimatrix The economical way to enter professional die cutting and embossing •

Impressive quality, flexibility and cost-effectiveness

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High productivity with minimum makeready times

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Max. 7500 sheets/h

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Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Dymatrix 106 CSB

The Dymatrix 106CSB with a cutting force of 330 tonnes

© Heidelberger Druckmaschinen AG

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The Dymatrix 106 is a high quality system for cutting, creasing and embossing

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Sheet size of 76x106 cm

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Grammages 80 – 2,000 g

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Corrugated board up to 4 mm

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Also special materials

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Register systems in all stations such as feeder, cutting, stripping and blanking

Postpress Overview – Trends and Technologies

Febr. 2007

Hot foil stamping module - Integration with Dymatrix 106/113

• • •

Quick changeover between die cutting and hot foil stamping Modular and retrofitable Integrated user interface via touch screen for hot foil stamping and die cutting

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Postpress Overview – Trends and Technologies

Dymatrix 142 CSB • •

Max. sheet size Speed

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1020x1420 mm 8000 sheets/h

Febr. 2007

Postpress Overview – Trends and Technologies

The folding box

Major types of boxes (Carton, board and corrugated board) a) b) c) d) e)

FoldingFlappDouble wallShell & slideTuck-in boxes

© Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Scope of material for the folding carton gluers

• Board from 200 to 1,400 gsm • Corrugated board up to 20 mm heigth (folded)

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Postpress Overview – Trends and Technologies

Febr. 2007

Structure of a folder gluer pressing & delivery

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transfer

folding & gluing

preparation

feeder

Postpress Overview – Trends and Technologies

DIANA

© Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

The Heidelberg Diana X 135 A new generation of folding carton gluers

Maximum flexibility due to modular design • Almost endless series of customized module combinations • Servo drive technology at every section • Turning Module allows precise and efficient processing of special cartons •

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Postpress Overview – Trends and Technologies

Diana X - FleXibility through Modularity Basic machine for standard applications

Universal machine for varying applications

Customized configuration for special applications

Š Heidelberger Druckmaschinen AG

Febr. 2007

Postpress Overview – Trends and Technologies

Febr. 2007

Commitment to the Folding Carton Industry

Internet Customer/ Supplier

Delivery

Finishing

Prepress

Soft and Hardcopy Proofs

Offset

Printing Process

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CtP

Postpress Overview – Trends and Technologies

Febr. 2007

FCS 100 (Finishing Communication System) Production Data Management PDM • Precise recording of operational data • Online retrieval of production state for better disposition • Transfer of the economic data to DataControl or Prinance

Compufold Workflow CFW • Calculation of folding programs • Catalogue with 81 folding techniques • Processing of CIP4/PPF data Compustitch Workflow CSW • Calculation of preset values for gatherer-stitcher • Loading of CIP4/PPF data • Automatic format setting © Heidelberger Druckmaschinen AG

Postpress Overview – Trends and Technologies

Febr. 2007

Thank you very much for your attention !

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