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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
“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
• • • • • • •
• • • • • • •
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
© Heidelberger Druckmaschinen AG
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.
Š Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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. •
3 counter-rotating folding rollers • Buckle plate with an adjustable sheet stop • Non-cyclic, continuous production
© Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
The knife fold technique is always combined with the buckle fold technique • • •
• •
•
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
© Heidelberger Druckmaschinen AG
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
• •
• • •
• •
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
© Heidelberger Druckmaschinen AG
Combination folder
•
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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)
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
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
•
•
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.
© Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Speedbander – Customer Benefits
•
• • • • •
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.
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
Febr. 2007
Postpress Overview – Trends and Technologies
Twin Stacker – Customer Benefits
•
•
•
• •
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
© Heidelberger Druckmaschinen AG
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
•
•
•
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
© Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
Thread-sealing – time-saving, due to inline production
• •
• • •
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
Thread mover
Piercing needles
Postpress Overview – Trends and Technologies
Febr. 2007
Thread-sealing technique
Thread clamp
Folded sheet
© Heidelberger Druckmaschinen AG
Puncture needle
Laydown and sealing tool
Pressure element
Postpress Overview – Trends and Technologies
Thread-sealing – Inline production
© Heidelberger Druckmaschinen AG
Febr. 2007
Postpress Overview – Trends and Technologies
Adhesive binding
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
Eurobind 500 1-clamp professional perfect binding machines for single sheet and signature / folded section applications
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
The Heidelberg Eurobind 4000 System •
IPEX 2006 was the official launch of the sytem
© Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
First Public Trade-Show Presentation of Eurobind 4000
© Heidelberger Druckmaschinen AG
Febr. 2007
Postpress Overview – Trends and Technologies
First Public Trade-Show Presentation of Eurobind 4000
© Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
ST 100 – the specialist in the A4 range
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
© Heidelberger Druckmaschinen AG
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
© Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Febr. 2007
ST 450 – the gatherer-stitcher with the revolutionary concept allows for high flexibility
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
Š Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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
•
High productivity with minimum makeready times
•
Max. 7500 sheets/h
© Heidelberger Druckmaschinen AG
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
•
The Dymatrix 106 is a high quality system for cutting, creasing and embossing
•
Sheet size of 76x106 cm
•
Grammages 80 – 2,000 g
•
Corrugated board up to 4 mm
•
Also special materials
•
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
© Heidelberger Druckmaschinen AG
Postpress Overview – Trends and Technologies
Dymatrix 142 CSB • •
Max. sheet size Speed
© Heidelberger Druckmaschinen AG
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)
© Heidelberger Druckmaschinen AG
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 •
© Heidelberger Druckmaschinen AG
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
Š Heidelberger Druckmaschinen AG
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 !
© Heidelberger Druckmaschinen AG