Muller Martini Panorama, 2010, Spring by Polygraphimport Webman

The magazine for Muller Martini customers

Muller Martini Standardizes Service Portfolio with New MMServices Label and Creates a Direct Link to Clients with MMRemote

Spring 2010

Editorial

Improving the Lifespan of Your Equipment with MMServices

Bruno Müller, CEO Muller Martini

E Fulfilling quality requirements while keeping unit costs low, is particularly challenging in the graphic arts industry, and the competition has further intensified on all levels. This includes the printing plants and finishing operations, as well as the various media. The virtually unrestricted availability of information in electronic media and the variety of printed media have changed reading behavior and the way in which information is used. The ready availability of machines, efficient production, secure processes and individually customizable end products are all requirements necessary to allow the graphic arts industry long-term success. As someone who uses our equipment, Muller Martini wants to ensure that you can fully exploit the potential of your machines and systems. If we manage to impress you and exceed your expectations, then we have achieved our goal. It is our express aim to sustainably improve your results by means of a continuous optimization process, thus strengthening your market position.

Make use of the tailor-made MMServices from Muller Martini, which can be individually customized to meet your requirements and you could profit even more from Muller Martini’s global service network, service expertise and extensive specialist knowledge. We offer comprehensive, process-oriented and effective services and want to tailor them specifically to your process-relevant needs. The contents of the new MMServices package, which we will start in the coming months in all Muller Martini companies, are flexible. A detailed description can be found on 7 of this edition of “Panorama”. MMServices can be used individually or combined perfectly with one another. Alongside the reliable on-site service, our comprehensive spare parts delivery service and the proven training program for machine operators, MM Services ensures that your investments in our machines meet your expectations throughout their service life – or even exceed them. Using MMServices, we want to improve efficiency, extend the use and lifespan of

the machines and therefore improve the quality of your systems. We are especially looking forward to these challenging tasks. Let us make a start at IPEX 2010! Join us from the 18th through to the 25th May in Birmingham, in hall 19, stand C750.  I’m looking forward to meeting you! Yours sincerely

Bruno Müller, CEO Muller Martini

Muller Martini Panorama Spring 2010

Contents

Imprint

Volume 25 Muller Martini “Panorama” Editor Dr. Markus Angst markus.angst@ch.mullermartini.com Publisher Muller Martini Marketing AG Untere Brühlstrasse 13 CH-4800 Zofingen, Switzerland Telephone +41 62 745 45 75 Fax +41 62 751 55 50 www.mullermartini.com

4 Intensive pricing pressure and tight deadlines: Graphics companies rely on good production system availability.

18 CI down to the last detail: Reclam has opted for a yellow Bolero line to perform perfect binding on its legendary “little yellow books” – it is the first bookbindery in the world to do so.

31 The revolutionary Variable Sleeve Offset Printing (VSOP) technology has opened up new market potential for printers.

Publication frequency Appears three times a year in English, French, German, Italian and Spanish editions. Reproduction with reference to source is permitted. Printed in Switzerland.

Services Maintenance, Training, Data Analysis – Utilizing the Full Machine Potential

Press Delivery Systems UPC, Vaasa – Cell Phone Cameras Boost Circulation of Printed Products

Cert no. IMO-COC-025036

Sales and Service Muller Martini Ltd. Ridgeway Industrial Estate Iver, Buckinghamshire SLO 9JQ Phone Iver 0845 345 3588 Telefax 65 56 58 (Std Code 01753) info@gb.mullermartini.com www.mullermartini.co.uk Muller Martini Panorama Spring 2010

Digital Book Production RR Donnelley/Muller Martini – Inline Print Engine and Book Production System

Saddle Stitching Systems France – Cloître, Valblor and Ferréol Put their Faith in the New Primera

Softcover Production IBW, Oostkamp – Two CoronaCompact CC12s with New 3696 Gathering Machine Reclam, Ditzingen – A Bolero in a “Yellow Jersey” for the “little yellow books” Masar, Dubai – Higher Printing Capacities Necessitate Efficient Processing Fuisland, Singapore – Better Return on Investment with the Pantera C.O.S., Singapore – Quick Changeovers Required on Small Runs

15 18 20 22 24

Interview Alfred Ang – “Modern Systems Help Singapore Compete”

News

Hardcover Production Chiat Cheong, Penang – Two Concepts with the Diamant 35

Printing Presses Muller Martini VSOP – Variable-Size Printing for Optimum Flexibility Imprenta Nacional, Caracas – The Concepta is a Perfect Match for the Concept

30 34

Newspaper Mailroom Systems CSQ, Erbusco – A New Complete Line Including Stitching and Cutting Naples Daily News, Florida: Two SLS3000s Boost Flexibility Mu¯kusala, Riga – The ProLiner Matches Up to Tight Production Windows

36 38 40

Our program

Services

Using Optimum Servicing to Make Full Use of Your Machine’s Potential As a result of significant pricing pressure and increasingly narrow deadline windows, graphics arts companies are reliant on high levels of availability from their production systems. Muller Martini’s service package, MMServices, which made its worldwide debut at IPEX 2010, is the solution to these challenges. The program reduces downtime, improves productivity and reduces costs through production improvement, regular maintenance and in-depth training. The program provides the customer with everything they need to handle the pressure of the current market conditions. E A pilot program, based on aggressive production goals, was initiated at the Worldcolor Fairfield facility, targeting the Corona C13 perfect binding line. Muller Martini and the local management and operations staff collaborated in the new program, between 2007 and 2009. The targets were met and exceeded and, have become the norm for the future. Building on this experience, further collaboration improved throughput on the three Diamant 60 booklines, resulting in sustainable efficiencies in the 10% to 15% range. While the initiating force was extensive maintenance, the development of a scheduled maintenance program, targeted training, the availability of an eLearning module from Muller Martini USA for the operators, as well as an ongoing educational program has enabled the improvements to remain consistent. Long Term Efficiency “When we talk to our customers, we have

to lay all our cards on the table, talk openly, and point out the absolute importance of efficient operation, regular maintenance, and critical analysis of the machine production data,” says Werner Naegeli, Managing Director of Muller Martini USA. “We always seek out a solution together.” This was the case when Worldcolor sought to improve the productivity and output of a perfect binder and its three book lines, in Fairfield. “We were responsible for part of the issue, so we committed to making some machine upgrades,” Naegeli openly states. Gary Durand, Executive Vice President of Operations, at several Worldcolor book plants, added, “continuously improving our operations and productivity is a Worldcolor mandate. So, we engaged Muller Martini to partner with us. Together, we assessed the situation, formed an improvement plan, and initiated a program to achieve our improvement goals and objec-

tives. We were not content with a simple or quick win; but, rather, needed to put in place a long term continuous improvement solution to effect consistent, sustainable performance of both equipment and personnel.” Meeting Our Goals “The results of this collaborative effort have had tremendous operational benefits, from improved up time, to lower waste, to better equipment utilization, to greatly improved customer satisfaction. And, it would not have been possible without the total cooperation of Muller Martini,” added Mr. Durand. Encouraged by the results at the Fairfield facility, Gary Durand has directed his General Managers at the other Book and Targeted Publication plants, to embark on a similar program, again enlisting Muller Martini to partner with the local operators and management. The goal is to increase

“Prevention is Cheaper than a Cure” “Investing in the service is guaranteed to pay off” – Gary Durand, Executive Vice President of Operations, Worldcolor (USA) says in an interview with “Panorama”.

“Panorama”: Why did you opt for the service package from Muller Martini? Gary Durand: It is always better to be proactive rather than reactive. It is the best way to stay ahead of the curve. In other words, prevention is cheaper than a cure. Besides, by providing the necessary training and reliable equipment to the people who have to make the systems work, it frees them up to concentrate on the more

important things like quality and waste containment. It also improves employee morale. That is why we targeted a long term AfterCare Program solution. What makes Muller Martini and its service package stand out from other providers? Who better knows their equipment? Beyond that, Muller Martini showed a willingness and the enthusiasm to partner

with us. That made the decision easy. Muller Martini went a step further to provide customized, individualized solutions to meet the various specific requirements. We have found that their responsiveness is better than the industry average. That is why we have shared the impressive results with other equipment suppliers, with the expectation that we can broaden the program across our entire platform. Muller Martini Panorama Spring 2010

Marcus Stich, Head of Service Automation at Muller Martini Printing Presses GmbH, has a direct line to many printing presses all over the world (photo shows the Alprinta web offset printing press in use at Labelmakers in Australia).

the reliability of the various production systems by availing themselves of a measurable and responsive service program, centered around a formalized AfterCare Program. Werner Naegeli is in complete accord, given the severe economic challenges that we face. “In view of today’s commercial issues, our service package is primarily aimed at helping our customers optimize the capabilities of their equipment. They are very aware of the how important these investments are and realize that over time it is critical to continually train operators and maintain equipment in order to improve profit and growth. We, at Muller Martini, are honored and anxious to partner in these efforts.” Customers are Delighted In addition to the efficiency aspect, Gary Durand points to enhanced quality as a direct result of the maintenance and training program. “Nothing makes it easier to get in

Given the impressive results at your Fairfield facility, will you be putting service packages into other Worldcolor plants? I have already presented the results to all of my General Managers, and have assured them that, “investing in this service is guaranteed to pay off”. Training and maintenance will be a major focus going forward.

Muller Martini Panorama Spring 2010

front of a customer like a quality product delivered on time,” says Gary Durand. “Thanks to this program, we have been able to take advantage of such opportunities. Durand proudly recalls some feedback from Karen Romano, Vice President of Production at Simon & Schuster; “In the face of difficult market conditions, our business requires ever more flexibility and speed to get just the right number of books out to just the right customers. Worldcolor Fairfield has proved to be an excellent partner in enabling us to realize vastly reduced cycle times, which translates into fewer returns of unsold books. Many thanks to the teams at Worldcolor and Muller Martini for recognizing that success comes from both the ability to respond to our customers needs and to produce the quality product that we demand.” Deadlines and Price Wars Karl-Heinz Becker, an authorized agent,

Technical Director and executive committee member with Kaufmann printing house in Lahr, Germany, is thinking mainly of his customers and internal costs when he talks about the high performance and availability of the six saddle stitchers and the perfect binder. “It is imperative that our systems maintain high production speeds; otherwise, we would not be able to meet our deadlines. Particularly with the high-output saddle stitchers, we cannot afford to produce below capacity, because then it starts costing money.” Markus Kowalk, Head of Service and Projects at Muller Martini Germany, is also aware of the growing importance of high availability, “because we are receiving printing and finishing orders, often at the weekend as well, with shorter and shorter deadlines. In these situations, machine breakdowns are fatal, and our customers count on technical support and spare parts being available very rapidly. In addition to

Gary Durand (right), Executive Vice President, Operations, Worldcolor (USA): “We want to go beyond achieving improvements in the short term; we also want to ensure long-term efficiency.” On the left: Werner Naegeli, President & CEO Muller Martini Corp. USA.

Services

10 –15%

At Worldcolor Fairfield further collaboration improved throughput on the three Diamant 60 booklines, resulting in sustainable efficiencies in the 10% to 15% range.

this, graphics companies are currently engaged in an aggressive price war. Our systems must run smoothly right around the clock, particularly in the large industrial nations with their correspondingly high wage scales.” The Direct Line According to Burkhard Kühne, Head of the Finishing Department at Kaufmann, it is often trivial things – like signs of wear on the feeders of the perfect binders – that reduce production speeds, particularly after a certain operating time. It should be noted that Kaufmann printing house employs its own mechanics and electricians to take care of all its technical service needs, which includes maintaining the production machinery. “So we can do a lot without any assistance,” explains Burkhard Kühne. “But there comes a point where we have to pick up the phone and ask the service engineers at Muller Martini for advice.” Karl-Heinz Becker believes it is tremendous advantage “that our technicians and their counterparts at Muller Martini know each other personally and get along well. This gives us a direct line from the workshop to the machine.” However, Becker is happy that both sides are still able to speak forthrightly. “It does not help anyone if we beat around the bush when there are real problems to solve.” A Profitable Service Contract In order to avoid unpleasant surprises, Muller Martini Germany has entered into service contracts with many of its customers. This is an investment that pays off for graphics companies, according to Markus Kowalk: “Our customers are constantly saying that the service subscription works 6

Karl-Heinz Becker (left), authorized agent, Technical Director and executive committee member with Kaufmann printing house based in Lahr, Germany: “In the case of our two high-output saddle stitchers, we cannot afford to produce below capacity, because then it starts costing money.” On the right: Burkhard Kühne, Head of the Finishing Department at Kaufmann.

out cheaper than correcting individual machine failures. For example, one bookbinder increased the net output of its saddle stitchers by ten percent over the last three years through regular maintenance.” And as Markus Kowalk from Muller Martini Germany and Werner Naegeli of Muller Martini USA are both keen to point out, this is exactly what all service activities are aiming to achieve: “We make sure that our customers are able to utilize the full potential of their machines.” Valuable On-The-Job Training Cost factors such as pricing pressure and maintenance staff are becoming increasingly important, so companies are only investing if an investment looks likely to provide benefits. “An increasing number of customers are recognizing the benefit of servicing and seeing that their money really pays dividends,” explains Markus Kowalk. And it’s not surprising when you take a look at the service statistics for Muller Martini Germany: In 80% of faults, a machine is up and running again following telephone support. Ultimately it is both parties, the customer and the machine manufacturer, that benefit from a professional service program. “We are on the company’s premises on a regular basis while production is in progress, so it takes even less time for us to incorporate customer feedback into improved solutions,” explains Markus Kowalk. “Our machine operators also prefer it if maintenance and training are carried out in their usual work environment in the form of on-the-job training,” he adds. “We also benefit from the fact that Muller Martini has approved technicians who are specialists on the respective machine types

and have been working in the job for a number of years, so they know the systems inside out.” “Bookbinders Are Inventors” Often, this also leads to informal contact that goes beyond the actual professional collaboration. “Bookbinders are inventors,” says Markus Kowalk. This is why the Muller Martini service engineers often exchange cellphone numbers with the machine operators who work for the bookbinders. Joint pizza parties have even been organized with the staff at Worldcolor in the USA! Gary Durand is satisfied with the result: “We have become a real team over time.” Gary Durand is also convinced that the future of an optimized service lies in the network between the machine manufacturers and their customers. Burkhard Kühne adds: “In future I imagine suppliers will proactively carry out evaluations for us online to detect any problems early and help us improve our processes.” Key Production Data Many of Werner Naegeli’s customers in the USA like to have reliable data on their production processes: “Detailed information – including fault data – enables them to manufacture better products and achieve a higher level of productivity. Consequently, production data analyses are becoming more and more important. “Muller Martini’s Connex digital workflow system is an example of a system that provides the tools to obtain this data on site.” A Minute Online Beats an Hour on the Road One person who regularly checks up on “his” systems installed all over the world is Muller Martini Panorama Spring 2010

“With MMServices we are providing added value for our customers” As deadlines become tighter and tighter and pricing pressure grows, printers and finishers cannot afford any machine failures. High availability is therefore paramount for any graphics operation. That is why Muller Martini is standardizing its service offering in the seven modules of MM Services, the new label that was unveiled in Birmingham at IPEX 2010. “It’s just like with a car,” says Daniel Nydegger, Head of Group Service

at Muller Martini. “The original manufacturer depends on having the best diagnosis. Brief, predictable machine downtimes help to prevent longer, unscheduled failures. By ensuring that the machine is operated in a way that retains its value for its entire service life, Muller Martini is creating added value for its customers – this is also true for existing machines.”

Startup Experienced specialists plan and manage projects – not only for new investments, but also when operations are restructured or expanded. Service professionals ensure that commissioning is executed rapidly and that process reliability is maintained from the very beginning.

Repair Because even the best equipment can fail, highly qualified service engineers are on hand to provide fast, professional assistance – by phone, remote service or on site. Original spare parts ensure uninterrupted, high-quality production.

Uptodate Regular updates prolong the life span of the machines and ensure that their high performance characteristics are maintained for many years. Because all Muller Martini equipment has a modular design, it can be retrofitted or expanded in line with new business models or market changes. A retrofit pays for itself very quickly.

Inspect The Muller Martini preventive inspection service keeps equipment in top condition, provides complete security in terms of production continuity and also reduces operating costs. Experts analyze the systems and report problem areas and (improvement) potential to the customer.

Marcus Stich. Using a remote solution, the Head of Service Automation at Muller Martini Printing Presses GmbH in Maulburg, Germany, can log into the Alprinta, Concepta, and Concept-NT web offset printing presses at his customers’ sites from anywhere in the world. Of course, he only does this at the customer’s request or with their express approval, and IT security is tested by the highly respected Technischer Überwachungs-Verein (TÜV). “With MMRemote, we can access all control components and drive systems directly – as if we were standing right in front of the machine. Just recently, when a cusMuller Martini Panorama Spring 2010

Remote Often with printing presses and in finishing, which is one of the very last production steps, every minute counts; Muller Martini’s customers therefore have a direct line to the manufacturer at all times. They can choose from three modules that can be combined and ex-

Improve Added value through training and advanced training – Experienced Muller Martini experts can provide operating personnel with a host of tips and tricks as well as thorough training. Customized training courses prepare machine operators perfectly for handling new equipment and keep them up to date with regard to developments and new features.

tomer’s industrial PC for machine operation crashed, we were able to reconfigure another PC that was integrated in the machine to take over the important function of operating the machine, and production resumed after a short interruption. All this without ever leaving Maulburg.” “A Good Feeling” Meindert Griek is Production Manager with Australian printing house Labelmakers, which runs an Alprinta. For him, MMRemote (see the box on page 7 for more details) and its 24/7 availability offers three major advantages. “Firstly, it was very helpful dur-

panded flexibly according to individual needs: MMHelp (24/7 support), MMRemote Access (online analysis, 24/7 support), MM Remote Online (teleconference, webcam, online analysis, 24/7 support).

Select The machinery must be serviced and inspected continuously to ensure efficient life cycle management. With a service contract based on predictable costs determined by annual price fixing, customers benefit immediately from the comprehensive, expert Muller Martini service program. MM

ing the installation phase, because the plant was able to support the service engineers on site here via the Internet. Secondly, with the thoroughly useful Remote Maintenance module, the system lets us know when we have to carry out the prescribed maintenance work. And thirdly, there is a good feeling of security when we know that a malfunction will quickly be corrected – especially since we are in a completely different time zone.” 

www.mullermartini.com 7

Press Delivery Systems 1 Anyone using their cell phone to scan the Upcode into the street plan of Moscow printed by UPC Print, will receive information on businesses located in the corresponding areas of the city. The publisher’s printing costs for the street plan are covered by commission, which it receives every time an Upcode is accessed.

How Cell-Phone Cameras are Increasing Print Runs What on earth has a cell-phone camera got to do with a printing house? “A great deal,” says Sture Udd. His supermedia system “UpCode” is leading to a rapid increase in his print product runs. The products are finished at UPC Print in Vaasa (Finland) using systems from Muller Martini.

E “Video killed the radio star” sang British pop act Buggles in their number one hit 30 years ago. They were wrong though: motion pictures took nothing away from radio. “Multimedia is killing print,” is what many pessimists are saying today. “They are wrong,” says Sture Udd. This Finnish media expert is not only the founder and CEO of UPC Print, but also CEO of UpCode Solutions Ltd and the inventor of UpCode 8

– a system he refers to as “supermedia” that now has presence in 56 countries on the market. From Paper to Cell Phone UpCode cleverly combine printed paper with a cell phone (the fact it was invented in Nokia’s home country of Finland is hardly a coincidence). It employs the principle of “mobile tagging,” which involves using

a cell phone to scan a black-and-white square reminiscent of a jumbled-up chess board or a Tetris game. The UpCode reader software decodes the information stored in the printed 2D barcode (such as product information or sales promotions) and displays it on the phone’s screen in the relevant language. The software itself is free; the only fees are those for the network provider. Muller Martini Panorama Spring 2010

2 UPC has two of its own weekly direct marketing magazines for the Finnish market that go by the names of “Mega” and “Asuntolehti Bostadsbladet”.

3 Sture Udd, founder and CEO of UPC Print and Upcode Solutions Ltd. (right, in front of the Listo log stacker): “Many printed-product customers work is based on cost per product, but working on a cost-per-order basis makes much more sense.” Left: Tom Lindström (Country Manager, Muller Martini Finland).

15 to 20 Percent Increase in Sales “Many printed-product customers work based on cost per product,” explains Sture Udd. “Unfortunately, many traditional advertisers and printers do not realize that working on a cost-per-order basis makes much more sense. I can use a mathematical formula to prove that printing an UpCode on brochures, promotional leaflets and flyers increases sales by 15 to 20 percent. That is why print has a future, and why UPC Print is therefore more than just

a printing house – I prefer to call it a communication center.” Moscow Street Plan: Run of 150,000 instead of 30,000 Sture Udd gives us an impressive example in the form of a 300-page, perfect-bound street plan of Moscow, which he produces for a Russian customer. Until just recently, this plan was generated in a run of 30,000 copies, which then needed to be sold. However, with more and more drivers turn-

ing to satellite navigation, the run decreased rapidly. To combat this, the publisher implemented a shift in concept: The Moscow street plan is now produced in a run of 150,000 copies and is free of charge. It also features an UpCode on numerous pages, providing realtime and 24/7 updatable offerings for businesses based in the corresponding part of the city. The publisher’s printing costs for the city guide are covered by commission, which it receives every time an UpCode is accessed. This is

Press Delivery Systems 4+5 Press-finished products are cut at UPC Print by a Preciso and a Compacto rotary trimmer.

7 The Primera C140 from the new generation of saddle stitchers from Muller Martini is the latest investment by UPC Print.

6 The thin paper presents particular challenges for the Avanti and Vivo log stackers (image).

possible because Upcode allows you to identify the printed product from which it was accessed. Special Challenge for the Press Delivery System: Thin Paper In business since 1978 and with a workforce of 100 people, UPC Print has a number of external customers, 50 percent of whom are located overseas. But that’s not all: the company also has two of its own weekly direct marketing magazines for the Finnish market that go by the names of “Mega” (with a run of 100,000 copies) and “Asuntolehti Bostadsbladet” (40,000 copies). Both products are printed using the high-quality heatset process and are cut by a Preciso and a Compacto rotary trimmer. When it comes to its innovative products, UPC turns to innovative solutions from Muller Martini. Take the press delivery system, for example: When you’re dealing with up to 100 metric tonnes of printed paper a day, it is essential to have a flawless interface between printing and finishing. That’s why 10

UPC – alongside its two rotary trimmers, two Forte and Listo stackers and a Cohiba palletizing system for press-finished products – also has three log stackers from Muller Martini at its Vaasa site. The two Avanti stackers and single Vivo stacker are faced with particularly tough challenges because UPC primarily uses thin paper weighing just 50 grams – sometimes even less.

our finishing systems come from the same supplier, we save money (e.g. in the initial stage of a new machine) and benefit from synergies (because our machine operators can use all of the systems). It’s also a big plus on the service front, as it means I only have to deal with one contact. Muller Martini has never left us out in the cold when we’ve had a problem.”

PrimaPlus Puts the Primera E140 to the Test The logs are fed via a PrimaPlus commissioned in 2006 (Sture Udd: “That was our test, and Muller Martini passed with flying colors”) and a Primera C140 from the new generation of saddle stitchers from Muller Martini, which was introduced in the summer of 2009. There were two key factors involved in opting for Muller Martini solutions – Sture Udd explains: “First was the experience Muller Martini had built up in print finishing over the decades, and the second was the fact that I can obtain all my solutions from a single source. Because all

Coming Soon: A New Perfect Binder Sture Udd has always invested in the latest systems: with one exception. Only the modular binder he bought for adhesive binding back in 2008 – not via Muller Martini incidentally – was second-hand. Sture Udd openly admits, “that was a huge mistake, should have invested in the most recent adhesive binding system. As soon as the economic downturn is behind us, we are going to commission a new perfect binder from Muller Martini.”  www.upc.fi www.upcodeworld.com Muller Martini Panorama Spring 2010

Digital Book Production

Inline Print Engine and Book Production System for RR Donnelley Muller Martini is joining forces with RR Donnelley on a project aimed at setting up several industrial inline print engine and book production systems.

E The graphics industry is experiencing an ever-increasing demand for quick, reliable, and cost-effective digital printing solutions. In view of these requirements, RR Donnelley and Muller Martini have joined forces to set up several fully integrated, high-performance digital print engine and book production systems. The printing press, developed by RR Donnelley, runs at a printing speed of up to 244 meters (800 feet) per minute, and the fully automated book production system from Muller Martini is able to produce con-

sistently high-quality products at this speed. First SigmaLine with Pantera The new digital book production system from Muller Martini comprises a SigmaLine with an integrated Pantera perfect binder. Working in conjunction with the ProteusJet 1200 dpi digital printing press from RR Donnelley, the system is able to produce high-quality softcover books and book blocks for hardcover books in impressively short turnaround times. The SigmaLine from Muller Martini connects all processes in a single system, from prepress data to digital printing and finishing, thereby enabling fully automated production in a single work process – from the roll right up to the finished book. This consistent integration of all subprocesses supports extremely quick and cost-effective production of small print runs. “Collaborative Partnership” “We are delighted to be continuing our

long-standing business relationship with RR Donnelley,” says Bruno Müller, CEO of Muller Martini. “The diverse performance of our processing systems and continued innovative power have allowed Muller Martini to develop solutions that rise to the challenge of RR Donnelley’s increasing demand for digital processing technologies.” RR Donnelley Group President Dan Knotts is thrilled “that our ongoing collaborative partnership with Muller Martini has led to this important breakthrough for our clients”. He is confident that this integrated printing and binding system combines the industry-leading technologies of RR Donnelley and Muller Martini in truly magnificent style, producing innovative new solutions and consolidating RR Donnelley’s position as a technology leader: “This combination boosts production speeds and streamlines production processes in order to provide publishers with high-quality products and maximum production flexibility.” 

RR Donnelley and Muller Martini are joining forces to set up several fully integrated, high-performance digital print engine and book production systems.

Muller Martini Panorama Spring 2010

Saddle Stitching Systems

“Changeovers Are Much Easier than with Other Saddle Stitchers” Cloître Imprimeurs in Saint-Thonan near Brest, Valblor Groupe Graphique in the Alsatian town of Illkirch and Imprimerie Ferréol in Meyzieu near Lyon, are three well-known graphical design and production companies in France that have all placed their trust in the new Primera saddle stitcher from Muller Martini.

E It was a historical moment when Cloître Imprimeurs was presented with a CIPPI award at Print in Chicago last September. Never before had a French company received this coveted award. “We are of course extremely proud to accept this honor, since innovation has always played an important part in our company’s history,” explains the company’s CEO Jean-Yves Lenormand. Cloître: A Great Reputation Thanks to the Primera C130 and the Connex System Two Muller Martini solutions made a significant contribution towards Cloître’s CIPPI

award for the “Best Process Automation Implementation in Europe” category; namely the Primera C130 and the Connex digital workflow system. Cloître has fully integrated the new-generation saddle stitcher from Muller Martini along with the new eight-color printing press by Komori into the JDF workflow using the Connex system. Cloître’s decision to purchase the Primera C130, its first investment in a saddle stitcher from Muller Martini, was largely down to the ImpriClub. The cooperative incorporating 47 graphic design companies and a total 64 production facilities, which is celebrating its 20-year anniversary in

2010, evaluates the most suitable machines to run all the production processes for each of its members. “This means that our members do not have to spend a lot of time evaluating different machines each time they are looking to make a new investment,” says Jean-Yves Lenormand, current Chairman of ImpriClub. Quick Changeovers Are Important After carrying out assessments and comparisons between the different manufacturers of loose leaf binding machines, the Primera C130 was ImpriClub’s favorite, which according to Denis Cloarec, Head of Production at Cloître, was down to the

2 1 Jean-Yves Lenormand (right), CEO of Cloître: “We are proud of the CIPPI award, since innovation has always played an important part in our company's history.” In the center Head of Production Denis Cloarec, left Hervé Boucher of Muller Martini France. 2 Simple and comfortable operation – Linda Lagathu, operator of the new Primera C130 saddle stitcher at Cloître Imprimeurs.

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Muller Martini Panorama Spring 2010

quick job changeover time and in particular the automatic timing feature on the new saddle stitcher. The feeder and gathering chain are automatically synchronized, whereby prior to the start of production the optimum coupling position of the feeders is calculated based on the sizes entered. The feeders automatically engage in the calculated position and in the preset duty cycle via a pneumatic coupling. “Since we have eight job changes on average per shift,” explains Denis Cloarec, “quick job changeovers are hugely im portant.” Cloître does not produce high volumes, but instead a diverse range of printed products (“everything except newspapers,” Jean-Yves Lenormand) in two-up production, with runs of between 1,000 and 5,000 copies, almost exclusively for foreign customers. Few Errors Thanks to JDF Romuald Jousni, head of the finishing department, explains that since it is easy and comfortable to use, this helps the company achieve quick job changeover times. “Our six machine operators initially worked alone on the new saddle stitchers for one month, then in pairs and in each case discussed problems among themselves. We then attended a further training course held by the technicians at Muller Martini France, and since then all the machine operators have worked autonomously.” JDF integration offers great advantages for Cloître Imprimeurs, especially when it comes to production feedback with lots of detailed information about current and fi-

nalized jobs. “Even given our many small orders,” explains Jean-Yves Lenormand, “we save a lot of time because the error rate is extremely low, irrespective of the fact that the production capacity of our new saddle stitchers is twice as quick as the previous model we were using.” According to Denis Cloarec, the Asir 3 optical scanning system contributes considerably towards the low error rate and high level of satisfaction experienced by Cloître’s customers. “This is something we did not have before and it plays a major part in the final quality of our printed products.” Valblor Groupe Graphique: Lots of Changeovers Valblor Groupe Graphique is also a member of ImpriClub. CEO and company founder Vincent Valantin and Head of Production Patrick Blies witnessed in person the intensive quality tests that the ImpriClub carried out on the saddle stitchers at the Muller Martini plant. In contrast to Cloître, however, Valblor was already running a loose leaf binding solution from Muller Martini – the 1509 saddle stitcher, which it put into operation in 1977 (and later replaced by a competitor model). At the same time, Valblor also prints large runs of up to 300,000 copies. “With the exception of softcover and hardcover books, we produce the whole graphical range,” says Vincent Valantin. Valblor, which in choosing the Primera C130 has reverted back to Muller Martini, is known primarily for its high-gloss luxury magazines. These are printed and finished

Cloître Imprimeurs E Location: Saint-Thonan (near Brest). E Founded: 1937. E Employees: 110 (3 shifts). E Customers: 70% Brittany, 30% Paris region. E Muller Martini saddle stitchers: Primera C130 (6 feeders, cover feeder, JDF integration via Connex).

Valblor Groupe Graphique E Location: Illkirch (Alsace). E Founded: 1975. E Mitarbeiter: 220 (3 shifts). E Employees: Eastern France. E Muller Martini saddle stitchers: Primera C130 (6 feeders, cover feeder, Perfetto stacker).

Imprimerie Ferréol E Location: Meyzieu (near Lyon). E Founded: 1900. E Employees: 53 (2 shifts). E Customers: Rhone/Alps, Paris/ Marseille regions. E Muller Martini saddle stitchers: Primera C140 (6 feeders, cover feeder, Perfetto stacker), PrimaPlus (6 feeders).

for a number of fashion, perfume and jewellery houses in the Paris area. However, very few of the runs include hundreds of thousands of copies, therefore Valblor

4 3 Vincent Valantin (left), CEO and founder of Valblor Groupe Graphique: “Thanks to the Primera C130, we have increased our production capacity and flexibility.” Right; Alain Detry of Muller Martini France. 4 The multi-skilled employees at Valblor not only operate the Primera C130, they also operate other machines.

3 Muller Martini Panorama Spring 2010

Saddle Stitching Systems

6 5 Pascal Chalamette (center), CEO of Imprimerie Ferréol: “Thanks to our investment in the Primera C140, we are winning many new orders from long-established customers.” Left; machine operator Rodolphe Magnin, right; Alain Detry of Muller Martini France. 6 Ferreol produces many small-size products on the new Primera C140 in two-up production.

must perform lots of changeovers, and according to Patrick Blies the strength of the new Primera C130 is down to the fact that “changeovers are much easier than with other saddle stitchers”. He then adds, “the new Muller Martini saddle stitcher is much more ergonomic to operate than the earlier models. The operators are able to access the machine much more easily”. Multi-Skilled Machine Operators For Valblor this is not such an important factor, however, since none of its machine operators specialize on one particular system. “We train our employees to be multiskilled” says Patrick Blies. “It is therefore important that the machine is fully automated.” The Head of Production considers the touchscreen operation and the self-explanatory icons on the Human Machine Interfaces (HMI) a major advantage. “To say that saddle stitchers have been revolutionized would be a huge exaggeration,” comments Patrick Blies, “however, certain aspects have been improved and this makes our work much easier.” Valblor often uses the Primera C130 in two-up production. “This enables us to increase our production capacity and therefore our level of flexibility towards our customers” emphasizes Vincent Valantin. He then goes on to refer to the current economic situation by saying “companies 14

that make clever investments and offer good products are equipped for the future”. Imprimerie Ferréol: From 500 to 300,000 Copies The main reason that Imprimerie Ferréol also decided to invest in the Primera is, according to the company’s CEO Pascal Chalamette, because “We specialize in small-size products. We are now able to produce these in two-up production, which is far more economical.” Since Ferréol is now in a position to win large orders of up to 300,000 copies, in addition to its smaller orders from 500 copies, the company opted for the C140 – the most efficient system from the new generation of saddle stitchers from Muller Martini. “We were never able to produce on such a scale,“ emphasizes Pascal Chalamette. “However, thanks to our new investment we have considerably strengthened our position in the market and are winning lots of new orders from long-established customers.” Ferréol is a loyal partner of Muller Martini, with its Bravo S (up to 2005) and PrimaPlus (from 2005) and therefore has a great deal of experience with saddle stitchers, so it is easy for Pascal Chalamette to make comparisons between the innovations. “The upgrade from Bravo to PrimaPlus was a big step. Though the step from

PrimaPlus to Primera is an even greater step.” Time Savings Thanks to Two-Up Production Improvements to the feeders, the threeknife trimmer and the Perfetto stacker, which Valblor has purchased to complement its new Primera line, really caught the attention of Pascal Chalamette who, together with his brother Thierry and Finance Director Maurice Benjamin, is a co-owner of the company. Operating the machine is also more comfortable now. As an all-rounder, Ferréol produces a number of periodical magazines. “However, these are not our core business” says Pascal Chalamette. Ferréol’s main business comes in the form of commercial work in various different sizes, meaning that frequent and quick job changeovers are key. “Thanks to the automation of the Primera, this is now much easier. So in addition to the increased number of cycles and two-up production, we also gain more time, which is an important factor since customers want to receive their products even quicker.”  www.cloitre.fr www.imprimerieferreol.fr www.valblor.com www.impriclub.fr Muller Martini Panorama Spring 2010

Softcover Production

Shorter Production Windows and Fewer Night Shifts “We want to be ready for the recovery.” In keeping with these words, IBW Industrial Binding in the Belgian town of Oostkamp, commissioned two new CoronaCompact CC12 perfect binder lines along with the new 3696 gathering machine from Muller Martini within just four weeks.

The older and younger management team at IBW Industrial Binding brought together in one photo: front from left: Olivier van der Haert (Business Development), Steven van Belle (Technology); back from left: François van der Haert (Finance Director), Patrick van Belle (Consultant for Production/Technology), Luc Dosselaere (Product Manager Muller Martini Benelux), Bernard van der Haert (Delegate for the Supervisory Board).

Softcover Production

four, all of which are kitted out with the new VPN book spine nozzle for PUR production. The last two were commissioned in August and September of last year, in addition to two Acoro lines and a modular binder. In contrast to the two other CC12 lines, both new systems, which feature two three-knife trimmers from the new Orbit generation as well as a splitting saw and an Easy Fly face trimmer each, are fitted with the latest bookbinding innovation from Muller Martini – the 3696 gathering machine (also see info box). One has 16 stations, the other has 20.

1 E Thanks to over a million bound and saddle stitched products manufactured every day, IBW is not only one of the most important bookbinderies in the Benelux countries, but is also one of the largest in Europe. The array of machines in Oostkamp near Bruges is equally as impressive – in addition to ten saddle stitchers, IBW and its 170 employees operate seven perfect binding lines – all Muller Martini models. They invariably bind heavyweight magazines for

external customers (IBW produces many renowned women’s, fashion, car, and computer magazines), as well as catalogs, brochures, annual reports, and books. Two New Lines With the ZTM 3696 Part of the IBW’s basic philosophy, and not least for reasons of a back-up facility, is to assemble two copies of each machine type with an identical configuration. In the case of the CoronaCompact CC12, there are

90,000 Copies in 24 Hours “Both the new 3696 gathering machines provide us with considerably greater flexibility,” emphasizes Patrick van Belle. In the same breath, the long-standing IBW external consultant for production and technology also adds: “Today, a high degree of flexibility is a must for all modern bookbinderies, and for us it is even more significant, as we receive all our orders from external partners and the production windows are much shorter than they used to be.” For example, there is just a 24-hour turnaround time for an African women’s mag-

IBW – Perfect Partner for Large Orders One of the senior positions at IBW – a family-run company – is held by a woman: Sales Director Annick Vandenbussche. In her opinion, there are two main reasons why the traditional company has grown into one of the largest independent bookbinderies in Europe over the last 30 years. “On the one hand, we’re located in the logistical heart of Europe – within a 300-kilometer radius of many large printing houses in Germany, England, France and the Benelux countries. This makes us the ideal

Annick Vandenbussche: “We are investing using our own funds even during difficult economic times.”

partner for large orders. On the other hand, our strategy is to continue to remain financially independent of banks, as this enables us to invest using our own funds, even during difficult economic times – such as the recent investment in the two new CoronaCompact lines.” To meet the constantly increasing customer requirements in terms of quality, flexibility and efficiency, IBW has formed two specialist teams; one for sheet-fed offset customers and one for web offset/gravure customers. “We will ensure we also keep our recipe for success into the future, which is a long-term partnership with customers and machine manufacturers,” explains Annick Vandenbussche.

Muller Martini Panorama Spring 2010

The New ZTM 3696 – Flexible, Efficient and Easy To Operate The new Muller Martini 3696 gathering machine can process the widest range of products in its class; the machine can generate processing speeds of up to 12,000 cycles/hour and leaves no doubt about its flexibility. Not only does the line provide bookbinders with optimum flexibility to respond to varying orders, it also enables extremely efficient production. When producing complex magazines and brochures, single sheets and fold-out signatures can be fed reliably, cards can be electrostatically charged and inserts can be secured in-line. The compact design and

the large size range of the 3696 gathering machine are impressive. The flexible feeder range is a new feature for this performance range, and thanks to its modular construction, the 3696 gathering machine can be perfectly adapted to meet each customer’s individual requirements. The base-unit is equipped with two twin feeders as standard. These feeders can be replaced at any point with a sample gluer, a specialty feeder with longitudinal action or – a completely new feature – a handfeeding station.

The gathering machine control system also includes functions for sample gluer, speciality feeder, reject gate and transfer elements, thereby ensuring extremely short set-up and job changeover times. Thanks to a feature supporting loading from both sides, the changeover time required between jobs can also be further reduced by loading and producing on one side and preparing the next job on the opposite side.

1 All four CoronaCompact lines at IBW are equipped for PUR production with the new VPN book spine nozzles. 2 Both new 3696 gathering machines provide IBW with considerably greater flexibility. 3 The two latest CoronaCompact lines at IBW feature an Orbit three-knife trimmer.

azine (with a circulation of 90,000 copies), from receiving the signatures to dispatching the magazines to Brussels airport. Increasingly More Card in Softcover Patrick van Belle gives three aspects of the 3696 gathering machine that have considerably increased flexibility: On the one hand, it is quick to change feeders that in terms of optimized production are often moved from one line to another, and on the other hand the card gluers. While glued in and loose cards have long since become the norm with saddle stitched magazines, according to Patrick van Belle there is an equivalent trend in softcover production too. Before commissioning the 3696 gathering machine, IBW used to tip cards to a Muller Martini Panorama Spring 2010

saddle stitcher. “Now we can finally do everything in one step – and gain ourselves a lot of time in the process,” explains Patrick van Belle. The Book Data Center (BDC) is also a key aspect in the streamlined production. It records the relevant book measurement data for the entire perfect binder line, which can be accessed by the individual machines. “The fact that the 3696 gathering machine and the Orbit three-knife trimmer are automatically set up is another important step forward for both our new perfect binder lines,” stresses van Belle. “An Important Step into the Future” Thanks to the increased productivity of the individual systems, operations at IBW have

now been consolidated to run over two shifts instead of three. This has resulted in considerably fewer night shifts, which is an important cost factor in light of the current economic climate. IBW naturally senses the lull in the print sector, which is why its latest investment may initially come as a surprise. However, for Patrick van Belle this is “an important step into the future, leaving all avenues open to us: We want to be ready for the upturn”. 

www.ibwbinding.be 17

Softcover Production

A Bolero Sports “Yellow Jersey” For Reclam’s “Little Yellow Books” Corporate identity down to the last detail: Reclam – based in the south-western German town of Ditzingen near Stuttgart – is the only graphics company in the world to use a yellow Muller Martini Bolero perfect binding line, on which it produces its legendary “little yellow books”.

E The Tour de France has the “yellow jersey” and Reclam has the unique “yellow Bolero”: a hallmark that is characteristic of uniform corporate identity. The “little yellow books” produced by Reclam, which contain world literature classics in a handy small format, are not just well-known within Germany, but also around the world. “The color of the new perfect binding line

is a reference to our company and produces a wow factor for our customers,” says Production Manager Franz Dengler. “It also allows our employees to fully identify with the new machine.” Successor to the Trendbinder According to Managing Director Franz Schäfer, there are two main reasons why

Reclam Graphischer Betrieb, sister company of Reclam Verlag, chose to replace the aging Trendbinder – installed in 1995 – with a Muller Martini solution: “The long-standing partnership with Muller Martini coupled with its excellent service.” However, the full-service company, which employs 75 people in the technology department and uses two signature and web presses that predominantly print in single color, did not make it easy for itself and took a long time to assess the new perfect binder in detail. After all, besides the six million “little yellow books” published by Reclam itself each year in several languages, and making up around 30% of its revenue, the company also prints a large number of additional softcover products for external customers, including timetables (e.g. for Deutsche Bahn), calendars or industrial catalogs.

1 18

Muller Martini Panorama Spring 2010

1 Managing Director Franz Schäfer (center) and Production Manager Franz Dengler (left) in discussion with Peter Stein from Muller Martini Germany. 2 Uniform corporate identity: The new yellow Bolero by Reclam is set to give customers the wow factor.

Experts in Thin Paper Reclam specializes in particular in small formats and thin paper. “We can print on paper as lightweight as 30 gsm, making us experts in thin paper printing,” proclaims Franz Schäfer proudly. The fact that the company often prints in formats smaller than A6 format was an important factor in choosing the Bolero, as Reclam produces not only its “little yellow books”, but also many other booklets in two-up production. Therefore, the binding line includes a 21-station gathering machine, gauzing station, high frequency dryer, dry panel with two cooling towers, Frontero face trimmer (for the full-flap books increasingly common at Reclam), Orbit three-knife trimmer and CB 18 stacker as well as a splitting saw. Asir 3 for High Quality Franz Dengler is, however, not only enthusiastic about the color of the new perfect binding line, but also about that all-important increased flexibility and productivity: “Usually, production runs over a three-shift operation, but since the Bolero was commissioned (on which the clamps are given the names of famous German authors alphabetically), we are able to run our adheMuller Martini Panorama Spring 2010

3 The clamps on the Bolero are supplied with the names of famous German authors alphabetically. 4 Reclam produces its “little yellow books” in two-up production.

sive binding tasks over two shifts instead.” Above all, thanks to the Book Data Center (BDC), it is now considerably quicker to set up the line. “Our machine operators were positive in their comments about the automatic measurement device and it has become an essential part of our operations,” emphasizes Franz Dengler. Quicker production is coupled with high quality thanks to the bar codes printed on the majority of signatures. “The Asir 3 automatic signature image recognition system identifies all faults, which means we no longer receive any complaints from our customers,” says Franz Dengler. “The Asir code provides us with 100% reliability, which is of the utmost importance for sensitive products such as timetables and what’s more, we can also now use Asir 3 to check the covers on the perfect binding line.” Every Type of Gluing Need Met Managing Director Franz Schäfer was also impressed by how quick Muller Martini were to install the new perfect binder: “We didn’t lose a single day – the Bolero was assembled at a new location before the Trendbinder was dismantled, which meant

we could get production underway on the very first day.” Production Manager Franz Dengler is also impressed by the new Bolero’s different gluing options. Whether cold glue, PUR, hotmelt or two-shot primer, Reclam can now meet all customer requirements. The new Bolero is fitted with a high-frequency dryer, ideal for production using cold glue, which provides an optimal layflat effect, enabling softcover books to also be produced in-line at greater speed. 

www.reclam-print.de 19

Softcover Production

Increased Printing Capacity Demands Efficient Finishing Systems By using the new Corona C15 perfect binder, Masar Printing and Publishing in Dubai aims to support the establishment of its own publishing company while also promoting export trade. The Corona will soon be integrated into the Connex digital workflow system from Muller Martini along with the new PrimaPlus Amrys saddle stitcher.

Optimizing Processes with Connex When Masar Printing and Publishing was planning the new, giant production plant, one thing was clear according to General Manager Faisal Bin Haider: “In view of the variety of machines we have, a high level of integration of the various systems was an incredibly important factor for us.”

As a result, Masar opted for the Connex digital workflow system from Muller Martini as the connecting link to the Management Information System (MIS) from Hiflex. This will soon network the Corona C15 perfect binder and the PrimaPlus Amrys saddle stitcher as well as all the other ma-

chines. “If we want to be ready for new markets and to keep up with the best graphics companies in the world, we need to be equipped with state-of-the-art technology,” reflects Faisal Bin Haider. Connex has proved instrumental in helping us optimize our processes.”

Muller Martini Panorama Spring 2010

1 The Corona C15 line at Masar comprises a gathering machine with 24 stations, twelve stream feeders, two card gluers, two Zenith S three-knife trimmers, a CB 16 counter stacker and Fontana.

2 Faisal Bin Haider, General Manager of Masar Printing and Publishing (left): “Nothing we have seen rivals the Corona.” Right: Najib F. Awad, Deputy General Manager Sales at Giffin Graphics, the Muller Martini distributor in the United Arab Emirates. 3 The PrimaPlus Amrys saddle stitcher and the Corona C15 perfect binder are connected to the Connex digital workflow system.

E Masar Printing and Publishing can look back on a company history spanning nearly three decades, but until 2005 the company concentrated exclusively on newspaper/commercial printing and distribution of printed materials. “Four years ago we extended our field of business activities,” explains General Manager Faisal Bin Haider, “we became a fully integrated graphics business producing books and magazines.” Own Publishing Company and Export Trade April 2009 saw the next big step for the business. Masar, the Dubai-based printing arm of the Arab Media Group, the largest media group in the region, opened an impressive new production facility in the most prosperous flourishing industrial zone in the Middle East (IMPZ) at the gates of Dubai. It is here that the Corona C15 perfect binder and the PrimaPlus Amrys saddle stitcher finishing systems from Muller Martini were put into operation. The Corona C15 total solution, comprising a 24-station gathering machine with automatic Asir 3 signature recognition and 12 stream feeders, two card gluers, PUR and hotmelt gluing processes, two Zenith S three-knife trimmers (one of which is used as a backup solution), a CB 16 counMuller Martini Panorama Spring 2010

ter stacker, and Fontana pallet dispenser, will help Masar to achieve two objectives according to Faisal Bin Haider: “We want to deliver a fast turn around of printing jobs to produce quality products with zero errors. We also want to increase our export business to penetrate the international market.” Little Competition in Sight Masar, which employs a staff of 150, is investing heavily in new printing capacity to help it meet these objectives. Four sheetfed presses are already up and running in the new building; by the time the investment project is complete there will be eleven of these in total plus two Commercial Web printing presses all under one huge roof with the other equipment. The Corona C15 line, which is not yet operating at full capacity, will soon run around the clock to produce magazines and telephone directories in addition to books. Paper volumes will take on a whole new dimension following the extensive expansion, another reason why Masar has invested in fully automated finishing systems according to Faisal Bin Haider. “We visited several graphics businesses in various European countries and I saw nothing that could rival the Corona from Muller Martini in terms of performance, flexibility and

quality,” says the General Manager. As the machine operators at Masar were already experienced in using other Muller Martini perfect binders, the Corona C15 was fully functional practically from the first day it was commissioned. New Sizes on the PrimaPlus Amrys Saddle Stitcher The same applies to the PrimaPlus Amrys saddle stitcher that has been running since April 2009 with twelve pile feeders, cover feeders and card gluers, six stream feeders and a Cohiba automatic palletizer. “We had a Muller Martini saddle stitcher in our old factory that never let us down,” says Faisal Bin Haider. “The decision to use the same manufacturer was an easy one – particularly as we are able to produce some new sizes thanks to the PrimaPlus Amrys.” 

www.masarprint.com 21

Softcover Production

Entire Fuisland Team Opts for the Pantera Following Open House Event Using the Pantera from Muller Martini, Singapore-based company Fuisland Offset Printing (S) Pte. Ltd. is now able to produce 30,000 books in just one shift instead of the two it used to take – that’s quite some return on its investment in the new perfect binder.

E In October 2008, Png Eng Lee and a dozen employees from his company went to the Malaysian capital Kuala Lumpur to attend an open house event hosted by Muller Martini. For Fuisland’s Managing Director, the aim of this visit was to give himself and his employees the chance to take a closer look at the Pantera perfect binder: “I had already seen the machine a few months earlier at the drupa trade fair in Dusseldorf,” explains Png Eng Lee, “but I was on my own at the time and it’s also difficult to home in on the technical details when you’re at such a large event and surrounded by machines from so many different providers.” A Team Decision The open house event in Malaysia was nothing like the trade fair – this time the 22

Fuisland machine operators, technicians, mechanics, and electricians took the opportunity to gain much more detailed information about the Pantera from Muller Martini representatives. And just six months later, the new perfect binder was commissioned at Fuisland. “The entire team was involved in the decision to invest,” reveals Png Eng Lee, “it wasn’t simply down to the management.” Commissioning of the new perfect binder line, which includes a 12-station gathering machine, a criss-cross system for thread-sewn products (produced on a second-hand Muller Martini machine), and an Esprit three-knife trimmer, gave Fuisland the perfect opportunity to perform an extensive evaluation. Founded in 1996 and currently employing a staff of 50, this fullservice (prepress, printing house and fin-

ishing) company had for years been using a Muller Martini Pony machine. This was replaced by the new Pantera. Good Return on Investment Png Eng Lee reveals that although the old machine was dependable to the last, it did have one major disadvantage: production had to take place offline because the machine was not linked to a three-knife trimmer. Png Eng Lee quotes some example figures to provide an emphatic illustration of exactly what benefits the in-line solution with the new Pantera brings: “We now produce 30,000 books in a single shift. In the past it took two shifts to generate that volume. If we project that figure for an entire year, we’re looking at an improvement of almost 100,000 Singapore dollars* in the Muller Martini Panorama Spring 2010

operating results. Over the course of a decade, that amounts to almost a million dollars – and these figures are based on the single-shift operation approach we currently favor. If we were ever to adopt two-shift operation, the return on investment for the new machine would be even greater!” Comfortable Operation The benefits of the perfect binder are not limited to purely economic considerations; Png Eng Lee is also reaping the rewards of its technical capabilities: “The 30,000 books that we produce in each shift generally include ten different titles, which means frequent changeovers. With the Pantera, it’s truly a breeze. As some of our machine operators hail from China, it’s a big advantage for us that the touchscreen

1 Text books are still the primary source of business at Fuisland. Now that it has the Pantera, the company hopes to broaden its horizons with other perfect-bound products.

has displays in both English and Chinese.” The Pantera is currently used exclusively for hotmelt processes. It works at an average speed of 3700 cycles per hour (operating at 90% capacity). According to the Fuisland Managing Director, the support provided by Muller Martini Singapore in the weeks following commissioning was vital in getting his staff quickly up to speed on the new perfect binder: “Service is always a key factor for us; with both the Pantera and the Presto saddle stitcher that we acquired in 2001 we have only one line – there’s no backup system.” 90% Text Books The second big advantage in Png Eng Lee’s eyes is that the quality of the bound products clearly exceeds that produced with the

Pony: “We now receive lots of positive feedback from customers,” he tells us. Although around 90% of these customers are still in Singapore, Fuislands intends to boost its export figures. Currently, up to 90% of Fuisland’s business comprises text books and books of exercises and solutions for home study to complement school lessons. Now that it has the Pantera, the company hopes to broaden its horizons with other perfectbound products such as brochures, catalogs, annual reports, or magazines.  www.fuisland.com.sg

*approx. 70 000 US dollars

2 Png Eng Lee, Managing Director of Fuisland Offset Printing (right): “With the Pantera we produce 30,000 books in a single shift. In the past it took two shifts to generate that volume.” Left, Simon Leong, Sales Manager at Muller Martini Singapore.

2 Muller Martini Panorama Spring 2010

Softcover Production

Quick Printer Changeovers Make a Big Impact on Small Runs at C.O.S. Printers Among the specialties of Singapore-based C.O.S. Printers Pte. Ltd. are journals, which often entails small runs. As these products necessitate frequent production changeovers, the familyrun business has opted for the easy-operation Acoro A5 perfect binder from Muller Martini.

E C.O.S. Printers manages runs of between 100 and 10,000 copies per title and processes a wide range of sizes, all of which make one particular aspect of production an absolute priority: quick changeovers. According to company founder and Managing Director Alfred Ang, this is where the Acoro A5 perfect binder from Muller Martini really comes into its own: “As we rarely handle larger runs, high production speeds are not such an important issue for us. A quick ’make ready’ process, on the other hand, is vital.” This has particular relevance for the various (academic) journals that C.O.S. Printers handles, printing and processing runs of between 300 and 3000 copies for various specialist publishers the world over. 24

1 Director Alfred Ang, founder and Managing Director of C.O.S. Printers (left): “A quick ’make ready’ process is vital for us.” Right, Simon Leong, Sales Manager at Muller Martini Singapore.

2 C.O.S. Printers produces thread-sewn books using a Ventura from Muller Martini.

Production Director Derek Ang explains that the company’s machine operators find the Acoro A5, with its 20-station gathering machine and Merit S three-knife trimmer, extremely easy to operate: “The Commander is very clearly laid out, which has allowed us to get to grips with the line very quickly following a brief internal training session.”

sewn, which two years ago prompted the family business, founded in 1972 and now employing a staff of 80, to commission a Ventura thread sewing machine alongside the Acoro A5. “We were looking for a onestop solution,” says Alfred Ang, explaining why he decided to invest in the two Muller Martini systems. And his decision has really paid off for the company: “Our customers, 80% of whom are based outside Singapore, are happy with the quality we deliver. We’ve certainly never had any complaints, anyway.” 

One-Stop Solution As well as the journals and a few magazines, C.O.S. Printers also produces traditional text books and specialized scientific books, which students use as a supplement to their lessons and work through with their parents as an additional learning support. A lot of these books are thread-

www.cosprinters.com Muller Martini Panorama Spring 2010

Interview with Alfred Ang

“Modern Systems Enable Competitive Production” The small local market means that the strength of the graphic arts industry in Singapore traditionally lies in exportation, explains Alfred Ang, President of the Print & Media Association in Singapore. E “Panorama”: Being a city state in the heart of South-East Asia, Singapore and its manufacturing industry are highly export-oriented. Despite a huge amount of competition from surrounding countries with lower salaries, Singapore printers attract print jobs from all over the world. What are the strong points that make Singapore so attractive to overseas publishers? Alfred Ang, President of the Print & Media Association in Singapore: The population of Singapore is below five million, which makes its local market very small. This is why our graphics companies have always looked for customers overseas. Our perfect geographic location and excellent infrastructure – particularly the port – help us here, as does the fact that we Singaporeans are traditionally technology friendly. Many printing plants and book binderies therefore have modern, fully automated systems. This enables our production to be both efficient and competitive, and allows us to manufacture high-quality print products. Are there any printing products in which Singapore really specializes? Yes, we specialize in high-quality books with relatively low print runs, which are produced for publishing companies all over the world. Volumes and print-run development for magazines, catalogues, softcover and hardcover books have dropped in recent years in many parts of the world. What is the situation in Singapore, and what do you predict will happen in years to come? As mentioned previously, we have held a particularly strong position in short runs for a long time now, so this global trend has not really affected us. It is difficult to predict what we will face in the future. Perhaps we won’t simply print and bind anymore,

Muller Martini Panorama Spring 2010

Alfred Ang (right) is President of Singapore’s Print & Media Association and runs the family business C.O.S. Printers Pte. Ltd (founded in 1972) together with his brother Derek (see article on page 24).

but become more involved in the distribution process of our customers. Digital Book Production for short runs has experienced steady growth in the US and Europe. What about Singapore? Frankly, we are still in our infancy and the major industrial nations are way ahead of us. I expect it will be some time before we make such technological leaps; even with runs of 200 copies and offset printing, we still remain competitive.

tural changes. What does this mean for the printing industry in Singapore, and what challenges do you expect? I expect that we will need to increase cooperation in the future. Instead of battling against one another, we need to acquire orders together – as “Singapore Printing Ltd.” as it were – and then split them up into individual operations (which may be specialized in future). I definitely believe that the Print & Media Association needs to drive this process forward. 

Besides the economic crisis, the graphic arts industry is also facing major struc-

News from Müller Martini Ventura MC: 30% Less Air Consumption with Energy-Saving Ejectors

Mohn Media Opts for a Diamant MC 60 Bookline

New energy-saving ejectors enable an immediate reduction in compressed air consumption in the Ventura MC thread sewing machine. The small, compact generators provide the required vacuum both in the feeder hopper and in the signature opening station. They are connected to the compressed air supply and generate the vacuum for precisely as long as necessary and exactly where it is needed. These powerful ejectors significantly reduce the applied volume of air, resulting in distinct energy savings. As compressed air is an expensive resource, the bookbinder also saves money. In a comparable thread sewing production environment, the new components consumed around 30 percent less air. In addition, the response times at the beginning and end of the suction process are shorter because the volume of air need-

There’s no stopping the success of the Muller Martini bookline with MC technology in German bookbinderies. Following in the footsteps of Baier & Schneider, Pustet and Stein & Lehmann, Mohn Media has placed an order for a Diamant MC 60. The Gütersloh-based printing service provider, a member of the Bertelsmann Group, manufactures high-quality hardcover books and catalogs in four colors – frequently in large sizes. In addition to the Diamant MC 60, the in-line system chosen by Mohn Media also features a Merit three-knife trimmer, a Ribbon book ribbon inserting machine, a Vesta jacketing machine and a BLSD flow-through and end stacker. Following in-depth tests, Mohn Media was confident in its decision: The Muller Martini solution offers diverse options, outstanding reliability and excellent book quality, making

The Ventura MC thread sewing machine’s new ejectors significantly reduce the applied volume of air, resulting in distinct energy savings.

ing to be removed is kept to a minimum, meaning that the components not only save energy – they also enable greater process reliability.

CPM Internacional in Spain Upgrades Label Printing with a New Alprinta 74V

CPM Internacional, S.A. uses the Alprinta 74V primarily for film label types such as wrap-around and shrink sleeve.

Printing house CPM Internacional, S.A., based in San Martin de la Vega (Spain), has opted for a Muller Martini Alprinta 74V to expand its label printing capacity. The web offset printing press will be put into operation in spring

2010, right on schedule for the start of the busy period in beverage bottle labelling. “I am confident that we have acquired another high-quality, flexible item of production machinery in the Alprinta 74V,” explains Director Lucio Marina. “We need to deliver outstanding printing quality on our flexible materials.” CPM was particularly impressed by the outstanding printing quality delivered by the Alprinta 74V and the excellent print registration. The flexography printing unit is ATEX-approved; this means that solvent-based printing inks can be used and additional products can be produced using the machinery. Among the main products in its portfolio are roll labels, heat-shrink labels and flexible packaging, and CPM prints all the Coca-Cola labels for PET bottles in Spain.

it the ideal book production system to ensure high quality across the company’s wide range of products. Its production speed of 60 books a minute and its quick job changeover time also made it the perfect choice for each and every circulation size.

Following in-depth tests, Mohn Media opted for the Muller Martini Diamant MC 60 bookline.

More Than Double the Newspaper Inserting Efficiency at Newsprinters Newsprinters – part of the McPherson Media Group – in the Australian town of Shepparton, has increased the efficiency of its newspaper inserting process by a factor of 2.5 with the help of a new ProLiner from Muller Martini. In addition to the “Shepparton News Daily”, the flagship of the publishing company, Newsprinters prints around 30 daily, weekly and bi-weekly publications – as in-house productions as well as printing for other publishers. The ProLiner inserting machine from Muller Martini commissioned just a few months ago – the first of its kind in Australia – has a main section feeder, two pre-printed section feeders, six insert stations, and a PrintStack CN 80 stacker, allowing Newsprinters to add inserts and pre-printed sections online at full press speed. Chris McPherson is convinced: “This means we can produce

newspapers much more efficiently, particularly the thicker ones. In comparison to our previous solution, we are inserting two and a half times more inserts in each man hour.”

The Muller Martini ProLiner in use at Newsprinters is the first newspaper inserting system of this type in Australia.

Muller Martini Panorama Spring 2010

From left: Enrico Farinacci (Sales Director at Muller Martini Mailroom Systems), Ali Saif Al Neaimi (CEO UPP), Hans Peter Sutter (Muller Martini corporate management) and Volker Leonhardt (Marketing Director at Muller Martini Mailroom Systems) at the Muller Martini stand at IfraExpo in Vienna, Austria.

UPP in Abu Dhabi Expands Mailroom with ValueLiner Card Gluer

VF Tryck in Sweden Boasts the World’s First AlphaLiner with 18,000 Cycles

As well as commissioning a third SLS3000 newspaper inserting system from Muller Martini, United Printing and Publishing in Abu Dhabi, has added a new ValueLiner to its collection. The new card gluer from Muller Martini offers UPP some attractive opportuni-

VF Tryck, based in Karlstad in southern Sweden, is switching from hand work to automatic insertion with its new AlphaLiner. The tried and tested newspaper inserting system from Muller Martini has recently undergone a few modifications, which have increased its capacity by 20 percent to an exceptional 18,000 cycles. In addition to the company’s own daily newspaper “VF”, which is published six times a week and has a circulation of 22,000, VF Tryck also publishes five other newspapers and seven weekly magazines. In a typical print run, they produce between 2,500 and 185,000 copies, and each publication ranges from 8 to 72 pages. Until recently, inserts, editorial pre-printed sections and advertising materials were inserted manually, because the aging mailroom, which came from another provider, did not have an inserting system. FV Tryck decided to implement an automatic solution in order to respond to cost and time pressures. After a convincing customer visit to the site

ties for advertising on the front and back pages of newspaper products. It will increase UPP’s flexibility for publisher marketing and promises the organization an attractive ROI as well as additional added value in the mailroom. The “eye-catcher” effect on the front or back page of a newspaper generates high response rates and makes this form of advertising extremely attractive to advertisers. In 2007, Abu Dhabi’s biggest newspaper publisher – producer of the Arabic newspaper “Al Ittihad” and the new English-language daily “The National” – opted for a Muller Martini solution as a replacement for its existing newspaper mailroom. Two SLS3000 inserting systems were chosen, in addition to numerous other Muller Martini components, and then a third SLS3000 line was also added. In addition to the mailroom, UPP also invested in a Muller Martini press delivery system two years ago – with a Floorveyor conveyor, a Compacto rotary trimmer and a Forte stacker.

of a Swiss newspaper producer, the decision was taken to bring in the AlphaLiner – not least because the Muller Martini inserting system makes it possible to use different formats for the main section. “The AlphaLiner meets our needs perfectly,” enthuses Production Manager Daniel Johansson. “We also built up something of a partnership with the Muller Martini people during the planning stage, when they were on hand to provide advice in the first weeks after the system had been commissioned.”

VF Tryck has recently commissioned the first modified Alpha Liner newspaper inserting system from Muller Martini

“Impossible” Solutions Call for Innovative Finishing Systems Minimal setup times, high net output, ergonomic operation – three winning reasons why the An der Reuss AG bookbindery in Lucerne is investing in a new Muller Martini Primera E140 saddle stitcher. “Each individual printed product begins with an expert consultation,” explain Hansjörg and Urs Dietrich, the owners and managers of An der Reuss. “We work with our customers to find the best solutions – sometimes even solutions that really aren’t possible.” In order to realize these “impossible” solutions, the Lucernebased bookbindery is kitted out with ultra-modern production machinery that covers the entire finishing chain, from trimming, folding, binding and loose leaf binding to the house specialty, Muller Martini Panorama Spring 2010

index punching. An der Reuss, with a workforce of 40, commissioned its new Muller Martini Primera E140 a few weeks ago to replace its 235 saddle stitcher. The new line has an extremely user-friendly ergonomic design and features six feeders, one folder feeder, two blank stations with hand station, a quick transfer trolley enabling stations to be exchanged rapidly, a DS-459 three-knife trimmer with fourth and fifth knife attachment and a Perfetto stacker with Amrys. The decision to invest in the Primera E140, the flagship of Muller Martini’s new generation of saddle stitchers, was supported by the fact that this system boasts Amrys automatic size setup and can therefore be set to the required format quickly.

Brothers Urs (center) and Hansjörg Dietrich (right), owners and managers of An der Reuss AG, seal the purchase of their new Primera E140 saddle stitcher with Alois Hochstrasser (second from right), Director of Muller Martini Switzerland, and Roland Gautschi (second from left), Sales Director at Muller Martini Switzerland. On the left is Patrik Strotz, Production Manager at An der Reuss AG.

Hardcover Production

From Two Concepts to a Diamant 35 “A revolutionary step for stationery books,” exuberates Teh Aik Boon, Director of Chiat Cheong Sdn. Bhd. on the island of Penang, referring to the special production method adopted by his family business, whereby notebooks and logbooks printed with variable data on two Concept web offset machines are finished on a Diamant 35 bookline. E In the graphics industry, there may be scarcity value attached to the process of manufacturing on a hardcover bookline by printing the products on a web offset press and sending them on to an intermediate station via a PUR perfect binder, but this is the exact production method chosen by Chiat Cheong.

Notebooks and Log Books with Continuous Page Counts The reason for this is simple: In addition to text books for students, stationery books and increasingly redundant (computer) forms, the family-run business, which was founded in 1961 and employs 70 people, specializes in note books and log books

with continuous page counts for schools, offices, restaurants and security companies. “In order to print these products,” explains Teh Aik Boon, Director of the business and son of founder Teh Hoo Kim, who is semi-retired now, “I have two options. I can either use a sheet-fed press – but this

2 1 Because Chiat Cheong specializes in note books and log books with continuous page counts, the products are printed on two Concept machines and finished on the Diamant 35 bookline. 2 Due to space considerations at Chiat Cheong, Muller Martini not only had to ensure an exact layout for the Diamant 35 but also had to provide logistical precision work during installation. 3 From left to right: Lim Chooi Ing (wife of the Founder), Teh Aik Boon (Director), Simon Leong (Sales Manager at Muller Martini Singapore), Andrew Teoh (General Manager at Muller Martini Malaysia) and Abdullah Hanin (Service Engineer at Muller Martini Malaysia) in front of the new Diamant 35 bookline.

means a laborious finishing process because of the separation of the sheets – or I can use a web offset press, which performs the pagination process immediately and then folds the finished sheets.” More Efficient than Sheet-Fed Offset Teh Aik Boon is in no doubt that the roll to fold method (“a revolutionary step for stationery books”) is considerably more efficient than sheet-fed printing when it comes to producing his company’s main product. It prints an average run of 5.000 note book copies per type on two Muller Martini Concept machines with in-line variable data printing devices, which were commissioned in 1993 and 2002. After the folding procedure, the book blocks are prepared on a PUR perfect binder from another supplier and then finished into hardcover books on the Muller Martini Diamant 35 bookline, which was installed last November. Muller Martini Panorama Spring 2010

Until recently, the last stage of the production process was carried out by hand. “With the growing demand of our products,” explains Teh Aik Boon, “it was no longer feasible to do this in terms of the time it took.” Because Chiat Cheong – which produces up to 95 percent of its products for the local market – wanted to speed up the production (and, more specifically, the export) of printed diaries, Teh Aik Boon decided to invest in the Diamant 35, which is the first bookline of its kind in Malaysia.

“Panorama” also asked Teh Aik Boom whether service played a role in the decision. He just smiled: “Service? I can’t really comment on that. We don’t need service because our machines always run so well with regular in-house maintenance!” In addition to a paper storage facility, a new area with air conditioning was specifically set up for the Diamant 35 in order to ensure perfect quality of production. Due to space considerations, Muller Martini not only had to ensure an exact layout, but also had to provide logistical precision work during installation. 

Precision Work during Installation “The Diamant first attracted my attention at drupa 2004,” explains Teh Aik Boon. “In addition to the two Concept machines, we have also been using a Muller Martini 235 saddle stitcher since 1985. Because these machines have never let us down in all this time, we had no problems putting our trust in Muller Martini with the bookline too.” 29

Printing Presses

“Packaging Is a Company’s Business Card” It only takes a second for a consumer to choose a product when browsing through a store, which means eye-catching and relevant packaging is the key to successful sales. More and more food manufacturers are therefore choosing shrink sleeve labels – particularly for beverages and milk products. This year, Muller Martini is launching the new VSOP printing press with sleeve technology to establish itself as the market leader in web offset printing presses for package printing.

Good design isn’t just about the appeal; it’s about positioning the brand, and creating a positive link to the drink and its manufacturer.

E Unlike other sectors in the graphics industry, order volumes in package printing are currently quite good. This is because, even during economically difficult times, the consumer sector has shown itself to be relatively stable. One sector showing strikingly good production figures at the moment, despite the economic slump, is shrink sleeve printing. The annual growth rate of shrink sleeves in the food industry (beverages in particular) in the European Union is around 10 percent. Christian Steeb, General Manager of Nyco Flexible Packaging GmbH, which employs 170 employees in Kirchberg near the Swiss capital of Bern, has also noticed the trend: “In 2009, we printed 700 million shrink sleeve units. This year, it will be more than a billion.” 30

Deciding in Seconds One of the main reasons why more and more food manufacturers are choosing shrink sleeves for their beverages, yogurts, or salad sauces is the sheer limitless number of design and labelling possibilities. This is to account for today’s stressed-out shoppers, who decide whether or not to buy a product in a matter of seconds. This is particularly true of kiosks or similar sales outlets such as gas station shops. Marketing specialists call this the “moment of truth” at the point of sale. “With classic labels, there are limits as to the possible types of imprint,” says Christian Steeb. “With shrink sleeves, on the other hand, you have more room for maneuver.” According to Matthias Roth, Strategic Buyer at renowned Swiss bever-

ages manufacturer, Rivella AG in Rothrist, the increasing number of brands also has a major influence on packaging, and therefore on how packaging is designed and printed. “Products bought straight from the shelf are almost always chosen for their packaging.” Investment in Packaging While Rivella – a whey-based soft drink unchallenged in its market segment – traditionally has a paper label, the Michel fruit drinks that are also filled by Rivella AG have the better quality shrink sleeves. Ten years ago, Rivella only sold two products that used shrink sleeves. By 2005 this number had risen to seven, and now 13 products have shrink sleeves. And they are no longer called simply Michel Orange or Pineapple, Muller Martini Panorama Spring 2010

but Michel Bodyguard, Tinga, Beauty Colada, and Power Coffeeberry. “Shrink sleeves convey emotions better,” says Tatiana Giorgi, Project Manager, Marketing, Rivella AG, “and in such a hard-fought market as fruit juices, this is critical, particularly among the younger generation.” Just as important as quality, in fact. “Good design isn’t just about the appeal,” says Tatiana Giorgi, “it’s about positioning the brand, and creating a positive link to the drink and its manufacturer.” According to Tatiana Giorgi, it is precisely because Michel is a premium brand that does not compete with cheaper brands in the supermarket, that Rivella is prepared to add extra value to the product and invest in the packaging.

An aspect that according to Samuel Fueter, Head of Product Management Team Fresh at Switzerland’s largest dairy producer, Emmi, also believes is key for the premium product Caffè Latte. “However,” says Fueter, “the packaging must always match the overall concept.” For this reason, shrink sleeves seem almost tailormade for the conical containers of Caffè Latte, which since its launch in 2004 has become the most successful product introduction in Emmi’s history. New (Price) Dimensions Thanks to VSOP Technology . . . The manufacturing costs in the printing plant and processing costs at the filling machine are higher for shrink film than for pa-

per labels. However, the new VSOP technology (see box on page 32) makes shrink sleeves an increasingly attractive form of packaging, even in terms of price. Nyco, Europe’s number 1 in printing PET covers, produces food packaging using all three technologies – UV flexo for small orders, rotogravure for high-volume runs, and VSOP for small-volume and high-volume runs. VSOP has been in use for one year, originated from Drent Goebel, and is now managed by Muller Martini. “This allows us to compare the three variants with each other perfectly,” says Christian Steeb. And according to the General Manager of Nyco, the new technology fares well in the comparison for three reasons: “First, we have much less production waste with

“You also Taste With Your Eyes” Because shrink sleeves can be used for almost any shape, and allow a wide range of design possibilities, they have become increasingly popular – according to Samuel Fueter, Head of Product Management Team Fresh at Emmi in an interview with “Panorama”. Lucerne-based Emmi is Switzerland’s largest processor of dairy products, and operates one of Europe’s most innovative dairies. “Panorama”: What influence does the wide range of brands have on the sig nificance and design of shrink sleeves and labels? Samuel Fueter: We are in a saturated market in which the supply is much greater than the demand. As such, it is more important than ever to make sure our products stand out at the point of sale and present a perfectly designed image to the customer. Packaging plays a key role in the success of a product – and package finishing is part of this process. To what extent have shrink sleeves grown in importance in recent years? The popularity of shrink sleeves has exploded, not least due to their versatile design possibilities and the fact that they can Muller Martini Panorama Spring 2010

be used for almost any shape of packaging. More and more, we are attaching labels with additional information (promotions, information, booklets etc.) to the sleeves. You mentioned promotions: What effect do sales promotions have on the use of shrink sleeves and labels? Sales promotions for limited periods – such as discounts or multi-packs (3 for 2) – and other promotions need plenty of space for image and text, especially in a largely bilingual country like Switzerland. Therefore, we often use additional labels or accordion folds. Recently, though, we have also been using sleeves for promotions due to the major advances in sleeve technology, in terms of both double-sided printing and tear-off options. How important is high-quality package printing for your company? It’s crucial in the packaging industry. After all, you also taste with your eyes. A perfect image at the point of sale is therefore absolutely critical. How important is the cheaper production method of shrink sleeves with web

Samuel Fueter, Head of Product Management Team Fresh at Emmi: “Recently, we have also been using sleeves for promotions due to the major advances in sleeve technology, in terms of both double-sided printing and tear-off options.”

offset printing presses compared to rotogravure? With ever smaller lot sizes, web offset printing is a welcome alternative to rotogravure: In terms of print quality, it is almost equal to rotogravure. The lower costs for plates and reproduction are particularly advantageous. And the overall processing times from “ready-to-print” to delivery are also shorter. 31

Printing Presses

VSOP Printing Presses: Complete Order Change in Minutes Shrink film has to be printed onto a roll to be processed as a sleeve later. The most cost-effective method is to print on a VSOP (Variable Sleeve Offset Printing) web offset printing press. Thanks to sleeve technology, print sizes can be changed easily without having to exchange all the inserts. To change the printing unit on VSOP printing presses, only two sleeves need to be changed without tools. They are therefore infinitely variable to suit any image length. This means a complete change of

job is possible in just a few minutes, which makes VSOP machines ideal for small-volume and medium-volume runs. The VSOP printing presses from Muller Martini have three ink distribution rollers and tempered vibrator rollers. Combination printing using flexo, rotogravure, and screen printing methods are also possible. Termed VSFP (Variable Sleeve Flexo Printing), a flexo printing unit is available for a straight, horizontal web section – specially developed for electron-beam hardening

and wet-on-wet printing from offset to flexo. However, the VSFP printing unit is also available as a vertical version for UV flexo printing or for water-based printing inks in combination with a heatset dryer.

the VSOP machine. Second, the machines mean we need much less changeover time. And third, the printing method costs with VSOP offset technology are much lower than with rotogravure.”

“For us, it is of course a major advantage if we are able to reduce initial costs,” says Matthias Roth from Rivella. “Our run volumes today are much lower than they used to be due to the wider range of products, and the large number of sales campaigns and competitions.” “In the last ten years, the job volume has halved,” says Christian Steeb. With an up-

ward trend, a job printed on the Nyco VSOP today has an average of 10,000 running meters. The smallest job is 500 running meters, while the largest is 40,000.

. . . a delight for customers In turn, customers also benefit from the lower square meter price during printing.

Higher Register Accuracy And then there’s the print quality. Christian Steeb thinks that “his” VSOP, on which up to 99 percent of shrink sleeves are printed,

1 32

3 Muller Martini Panorama Spring 2010

1 Nyco prints up to 99 percent of shrink sleeves on its VSOP. 2 Christian Steeb, General Manager of the Nyco printing house: “The VSOP machine produces better print quality than rotogravure.” 3 Tatiana Giorgi (right), Project Manager, Marketing, Rivella AG: “Shrink sleeves convey emotions.” Center: Beatrix Geissmann, Senior Product Manager, Rivella AG; left: Matthias Roth, Strategic Buyer, Rivella AG. 4 From the roll to the bottle: Highly-automated shrink sleeve processing at Rivella AG in Rothrist, Switzerland.

4 produces better print quality than rotogravure: “In terms of the printing inks, the two technologies are at about the same level. But the register accuracy is better with our VSOP.” According to Matthias Roth, perfectly printed labels and shrink sleeves are an absolute necessity for established brands like Rivella and Michel: “The packaging is our

company’s business card. So we need the best print quality, and we therefore only work with the best printing houses.” 

www.mullermartini.com www.nyco.ch www.rivella.ch www.emmi.ch

New Business Models Thanks To VSOP Following the acquisition of the VSOP model series patent from Drent Goebel last year (see “Panorama” 3/09), Muller Martini has been able to offer a comprehensive equipment range in offset printing. The Muller Martini range of printing presses covers the requirements of a wide and unique customer base – from (traditional) forms and paper labels to extensive and versatile film wrapping, film labels, and shrink sleeves. “Our solutions,” says Hanspeter Pfister, Managing Director of Muller

Martini Druckmaschinen GmbH in Maulburg, “allow customers to implement promising new business models in the growth market of flexible and carton packaging.”

Machine Type

Printed Products/Markets

Web Width in mm

Since a complete change of job is possible in minutes, VSOP machines are ideal for small-volume and medium-volume runs.

Concepta 520

Mailings, forms, security printing, pharmaceutical inserts, labels, commercial work

Alprinta 520/740

Mailings, forms, security printing, pharmaceutical inserts, labels, commercial work

AlprintaV 520/740

Labels, pharmaceutical inserts, mailings, security printing

VSOP 520/850

Flexible packaging, labels, folding boxes

Muller Martini Panorama Spring 2010

Printing Presses

“The Concepta Fits Perfectly into our Design” Imprenta Nacional, the Venezuelan government printing plant in the capital city of Caracas, has used the Concepta from Muller Martini to significantly increase the production efficiency and the quality of their printed products. The investment comprises the new eight-ink web offset printing press as well as a BravoPlus saddle stitcher and a Bolero perfect binder, all from Muller Martini.

E The new generation of machines used by Imprenta Nacional to print for the government’s Ministerio del Poder Popular para la Communicación y la Información has not only paved the way for optimized setup times, but has also increased performance and productivity. The printing plant exemplifies the current rise in investments, which both South American state-owned enterprises and private companies have used to modernize their production machinery and bring themselves in line with international productions standards. Muller Martini makes significant contributions toward this development and has a presence in practically all of the leading Venezuelan printing plants thanks to the

huge success of Sucursal Venezuela, an agent affiliated with Muller Martini Mexico. The market position will be enhanced further by several projects in state-owned organizations, which are currently in the negotiation stages. Showroom for the Latest Technology Thanks to the investment in the new printing press and the various finishing systems from Muller Martini, the government printing plant has developed into a showroom for the most advanced technologies and is showing itself to be well-equipped for future production tasks. The company, which employees 200 people, produces a wide and constantly expanding range of printed

products for the government. Alongside daily official bulletin “Gaceta Oficial”, the company also prints books, brochures, magazines, posters and newspapers. Impressive Results Gabriel González, Director of Production for Imprenta Nacional, is proud of his new production machinery and appears very satisfied with the results achieved since commissioning: “The new Concepta is the center point of our modernization plan. It served as a replacement investment for four aging sheet-fed offset presses and its performance and reliability in terms of printing speed, product quality and versatility encouraged us to make the next step

1 34

Muller Martini Panorama Spring 2010

2 toward restructuring. While we have increased performance, our paper costs are lower than ever!” The Concepta has a web width of 520 mm and an operational performance of up to 305 meters per minute. The machine runs in a two-shift operation and is yet to meet a typographical test that it hasn’t mastered with distinction. For example, 5 million posters were printed in the highest quality in a continuous operation within two months. Gabriel González goes on to say that “thanks to its wide range of sizes, the Concepta is extremely flexible and can be used efficiently for both large and small runs. The new machine and its short set-up times form the core of our production and

cover our complete order spectrum. The Concepta is the perfect machine for our requirement profile and has proved itself to be the best when it comes down to production technology and cost-efficiency. Added to this is the flawless support service, provided to us on-site by Muller Martini.” BravoPlus and Bolero Imprenta Nacional has also set its sights on improving productivity in saddle stitching and adhesive binding, and has set new standards for Venezuela in production performance and operating convenience with the BravoPlus and the Bolero. Both Muller Martini finishing systems guarantee short set-up times, a wide range of product siz-

es, a high level of process reliability and the efficient solution for the most difficult of product requirements. “Every component of the extensive Muller Martini investment package has lived up to our expectations completely,” says Gabriel González. “They are tailormade for our set-up and provide a highly automated handling process that is really user-friendly. We achieve all of our production goals and are very satisfied with the performance and reliability of the systems.” 

1 The new Concepta eight-ink web offset printing press is the center point for Imprenta Nacional’s modernization plan. Pedro Balestrini, Managing Director of the Muller Martini agency in Venezuela (right), congratulates Director of Production Gabriel González on the new investment. 2 The Bolero perfect binder is the tailor-made solution for Imprenta Nacional’s softcover production. 3 Imprenta Nacional has also significantly increased productivity in saddle stitching thanks to the BravoPlus.

3 Muller Martini Panorama Spring 2010

Newspaper Mailroom Systems

CSQ Intensifies Magazine and Semi-Commercials Business with Stitching and Cutting Solution Only 18 months after commissioning its third Muller Martini inserting line, incorporating a stitching and cutting solution, Centro Stampa Quotidiani in Erbusco, Italy, is investing in a fourth complete line. This will enable CSQ to increase not only its production capacity (particularly for magazines), but also the flexibility of its mailroom.

E The fourth line at CSQ also contains core NewsStitch and NewsTrim III components for in-line stitching and cutting of magazines and semi-commercials. Like the other three lines, the fourth line also features NewsGrip-A conveyors, FlexiRoll buffers, a NewsLiner A inserting system, a NewsStack bundle building line with a

route address system, a packaging line (consisting of a film wrapping and cross strapping system) and an automatic ramp system. Three Daily Newspapers . . . The newspaper printing plant, which was founded ten years ago as a joint venture be-

tween newspaper publishers SESAAB and Editoriale Bresciana, produces four daily broadsheet newspapers seven days a week: E “L’Eco di Bergamo” (circulation: 60,000), E “Giornale di Brescia” (circulation: 60,000),

With inserts for the three daily newspapers “L‘Eco di Bergamo”, “Giornale di Brescia” and “La Provincia”, CSQ is able to increase utilization of its printing presses and the mailroom.

Muller Martini Panorama Spring 2010

1 E “La Provincia” (four different provincial editions for the Como, Lecco, Sondrio and Varese agglomerations – total circulation: 55,000), E “Avvenire” (circulation: 90,000). . . . And Numerous Weekly Magazines CSQ – which, in the early days had a workforce of 35 but now employs nearly 100 staff – also prints an increasing number of magazines, newspaper supplements and semi-commercials. “We have been attempting to boost this business for just over a year now, because we wanted to increase the utilization of our printing presses and the mailroom,” stresses CSQ Managing Director and qualified engineer Dario De Cian. CSQ produces all of its magazines for Italian customers, with the circulations for these magazines ranging from 5,000 to 50,000 copies, while the daily print volume amounts to tens of thousands of copies. Keeping All Our Options Open Eighteen months ago, in order to successfully establish itself in this new business segment, the printing house, which currently owns three coldset printing presses, invested in a complete mailroom system from Muller Martini, incorporating NewsStitch and NewsTrim III components for stitching and cutting. “This flexible system means we can keep all our options open,” explains Dario De Cian. “Our magazines and semi-commercials can be processed with covers in the NewsLiner, stitched and then cut in the NewsTrim, or we can stitch them directly in the printing press and cut them in the NewsTrim; alternatively, we can simply deliver untrimmed products Muller Martini Panorama Spring 2010

1 Dario De Cian, CSQ Managing Director (center): “The flexible mailroom system from Muller Martini enables us to keep all our options open.” Left – Alberto Giudici (Head of Maintenance/Systems/IT), right – Samuele Trovati (Product Manager, Muller Martini Italy).

that have been stitched in the printing press.” The Fourth Line Can Stitch and Cut Too! The deciding factor behind the installation of the fourth Muller Martini line just 18 months after the third was the company’s acquisition of a new printing press that would allow the daily newspapers to be converted from the “Rheinisch” format (38 x 53 cm) to the “Berlin/Italian” format (31 x 45 cm). “The buffer system impressed us from the very beginning,” explains Alberto Giudici (Head of Maintenance/Systems/IT), “and is proving increasingly important.” Given that this system had proved most successful and is perfectly tailored to the needs of CSQ, the newspaper publisher once again opted for a mailroom solution from Muller Martini with exactly the same

2 The FlexiRoll buffer system is playing an increasingly important role at CSQ. 3 CSQ produces numerous magazines with a daily volume amounting to tens of thousands of copies.

configuration. “As we needed a new inserting system for the new printing press anyway,” concludes consultant Dr. Carlo Antonio Goia, “we decided that opting for a second complete line, including the stitching and cutting components, would constitute a sound investment for the future. Our declared objective is to cut our production times for the magazines and bring them more into line with our newspaper production times. At the same time, the stitching and cutting system provides us with a back-up and therefore greater flexibility.” The fourth line is due to be commissioned in the coming autumn and, like the three existing lines, it features the Muller Martini Mailroom Production Control (MPC) system, which enables full monitoring and control of the mailroom workflow.  www.csqspa.it 37

Newspaper Mailroom Systems

Naples Daily News: Two New SLS3000 Series Insertion Systems Improve Flexibility and Performance As with the new printing press, for the mailroom Naples Daily News also attached particular importance to technologies that enable flexible, economic and highly-automated production. This is why the newspaper printer in Naples, Florida, decided to purchase two SLS3000 series inserting systems from Muller Martini.

Muller Martiniâ&#x20AC;&#x192; Panorama Spring 2010

With the two SLS3000 series inserting machines, Naples Daily News has a tailormade mailroom system that meets both the market requirements of today and those of tomorrow.

sion. The two SLS3000 series inserting systems with 32 and 22 stations have innovative features that create a range of production possibilities; this opens up completely new perspectives and options for us.” Optimized Production in Short Time Frames The SLS3000 series is not just a quick, flexible, easy-to-use inserting system that optimizes production in short time frames; it can also handle products that are thin and difficult to process, or that have an unusual format, in a safe way and with minimum production waste. The high production speeds of the Muller Martini inserting systems ensure strong productivity. The issue of zoning is also of great importance because Naples Daily News specializes in target group-specific marketing. The ability of the Mailroom Production Control (MPC) system to perform frequent zone changes without stopping is therefore clearly an essential factor. The insertion process is monitored by means of a programmable check that identifies missing sections or duplicates. The Missed Insert Repair System (MIRS) detects missing inserts and unopened main jackets and completes them.

E At Naples Daily News, the two SLS3000 series are at the heart of a mailroom solution conceived by Muller Martini. This also includes NewsGrip-A conveyer systems, which feature several receiving and delivery stations to ensure the quick and secure transportation of printed products produced on the new WIFAG printing press. Fulfilling Specific Needs For Thomas J. Sewall (Director of Operations) and Casey Cote (Press Room Manager) deciding on the complete solution from Muller Martini was the logical result of an extensive evaluation process, which involved assessing the engineering, perforMuller Martini Panorama Spring 2010

mance, efficiency and services of several manufacturers: “With its experience and expertise as a leading international finishing specialist, Muller Martini had the best understanding of how to fulfil our specific needs and install a tailor-made mailroom system that meets both the market requirements of today and those of tomorrow.” As with the new newspaper press, for the mailroom Naples Daily News also attached particular importance to technologies that enable flexible, economic and highly-automated production. Thomas J. Sewall: “Unlike our previous resources, the new systems represent state-of-the-art technology in a new performance dimen-

Quick Response to Market Requirements “The new inserting systems have not only enabled us to considerably increase our capacities,” explains Thomas J. Sewall, “they have also significantly improved our product quality once again. They have optimized our potential to respond quickly and flexibly to market requirements as well as to our customers’ needs. In terms of capacity, production performance, quality and variety of sizes, we have taken a huge step forward with Muller Martini.” 

www.naplesnews.com 39

Newspaper Mailroom Systems

Short Production Windows Possible Thanks to the ProLiner More and more inserts in ever shorter production windows: Poligra¯fijas Grupa Mu¯kusala, based in the Latvian capital Riga, relies on a Muller Martini ProLiner newspaper inserting system for the 25 newspapers it prints in house. E Traditionally, inserts have been inserted by hand at Poligra¯fijas Grupa Mu¯kusala. After commissioning a new heatset press in 2006, the (semi-)commercials, magazines and pre-printed sections showed rapid growth until the current economic recession took effect, which is not surprising given that Mu¯kusala produces 25 newspapers, mainly tabloids distributed throughout Latvia and neighboring Lithuania: nine dailies, eleven weeklies and five periodically published titles. “In order to enable the short production window between 7 pm and 2 am to contin-

ue, we have replaced hand work with an automatic inserting system,” explains Director Visvaldis Trokša, who is also Chairman of Board, Association of Latvian Printing Companies (LPUA). Visvaldis Trokša goes on to say that the decision to acquire the ProLiner with five stations was also influenced by the fact that the company has good experience of Muller Martini, having also commissioned a BravoPlus saddle stitcher. “The ProLiner project was also handled professionally by our partner. We particularly appreciated the excellent training and the valuable tips,

which have enabled us to quickly improve our production processes. And if ever we have a problem, Muller Martini is swift off the mark to provide a solution.” The ProLiner is used both in-line and offline by the printing plant, which is Latvia’s second largest with 91 employees and was founded in 1994. “We use it off line, particularly at low speeds,” explains Head of Production Division, Sergejs Belouss. “The products are conveyed to the Forte stacker (which we also use for newspapers) before they are inserted in the ProLiner.”

Latvia’s second largest printing plant, Poligra¯fijas Grupa Mu¯kusala, produces 25 newspaper titles.

Muller Martini Panorama Spring 2010

2 1 The ProLiner newspaper inserting system is used both in-line and offline at Mu¯kusala. 2 Director Visvaldis Trokša: “The excellent training and the valuable tips provided by Muller Martini have enabled us to quickly improve our production processes.”

The Compacto is More Than a Match for the Speed of the Printing Press In contrast, the Muller Martini Compacto rotary trimmer operates invariably in-line. Since some of the numerous magazines and promotional leaflets with print runs between a few thousand and 47,000 copies are being produced increasingly for the export market, the rotary trimmer is used to perform three-sided trimming. “One particularly significant advantage of the Compacto is the high cycle time,” explains Muller Martini Panorama Spring 2010

3 The BravoPlus saddle stitcher was the first Muller Martini solution to be implemented at Poligra¯fijas Grupa Mu¯kusala. The company’s good experiences here contributed significantly to the decision to invest in the ProLiner news paper inserting system. Image shows Head of Production Division Sergejs Belouss.

4 The Compacto rotary trimmer’s high cycle time is more than a match for the output of the new printing press.

Sergejs Belouss, “it is completely up to the job of handling the output of our new printing press, which generally runs around the clock.”

stacker, bundle film wrapping machine and shrink tunnel. Because the saddle stitched products increasingly contain inserts, Mu¯kusala commissioned an Onyx/Rubin inserting and film-wrapping line two years after the BravoPlus was brought into play. 

BravoPlus Followed by Onyx/Rubin High-quality magazines printed for Mu¯kusala’s own publishing company and for other publishers, and also exported to Scandinavia in some cases, are processed on the BravoPlus saddle stitcher with six feeders, a merchandise tipper, Robusto

www.pgm.lv 41

Our program Printing Presses

Press Delivery Systems

Saddle Stitching Systems

Web offset presses Alprinta 52 520 mm (20½”) 365 m/min (1,200 ft/min) Option: 457 m/min (1,500 ft/min) Alprinta 74 740 mm (291/8”) 365 m/min (1,200 ft/min) Option: 457 m/min (1,500 ft/min) Alprinta 52V 520 mm (20½”) 365 m/min (1,200 ft/min) Alprinta 74V 740 mm (291/8”) 365 m/min (1,200 ft/min) VSOP 520 New 520 mm (20½”) 365 m/min (1,200 ft/min) VSOP 850 New 850 mm (33½”) 365 m/min (1,200 ft/min) Concepta 520 mm (20½”) 305 m/min (1,000 ft/min) Option: 365 m/min (1,200 ft/min)

Conveyors Floorveyor Topveyor Newsveyor

Saddle stitchers Valore Presto Presto E90 New Primera 110 New BravoPlus Primera 130 New PrimaPlus Primera 140 New Optima Tempo 22 Supra Compensating stackers Apollo Perfetto Robusto

Sheeter Q74 Q74 H

740 mm (291/8”) 365 m/min (1,200 ft/min) 740 mm (291/8”) 365 m/min (1,200 ft/min)

Sheeter with stacker QS52 520 mm (20½”) 305 m/min (1,000 ft/min) Option: 365 m/min (1,200 ft/min) Accessories/Special capabilities/Options Reinsertion for repeat web passes Remote ink fountain control Register control Closed-loop color control New Semi-automatic ink density control Video web StretchCorrect New 100% print inspection system Non-stop unwind and rewind Corona treatment Web cleaner Automatic blanket wash-up UV drying Electron beam curing (EB) Varnishing unit and flexo unit Flexo insert to offset print unit Screen printing unit Digital printing unit Numbering in the offset printing unit Label die-cutting (insert in processing station) with waste removal Insert change system on rails In-line laminating station Non-stop matrix removal

Trimmers Compacto Preciso Preciso N New Preciso DS New Preciso DS N New

Packaging Listo New up to 100,000 cycles/h Forte up to 100,000 cycles/h Static blocking unit 0457 up to 30 stacks/min Apila New automatic palletizer up to 16 stacks/min Cohiba automatic palletizer up to 26 stacks/min Fontana automatic palletizer up to 32 stacks/min Bundle stackers Vivo AvantiPlus Maximo Automatic palletizer 443 Roll systems PrintRoll P220 FlexiRoll

cycle time 50 sec cycle time 32 sec cycle time 20 sec

120,000 cycles/h 120,000 cycles/h

Digital Book Production SigmaLine total system New SigmaControl SigmaFolder SigmaCollator SigmaBinder SigmaTower SigmaTrimmer SigmaLine partial line New SigmaBinder SigmaTower SigmaTrimmer

up to 8 mm up to 13 mm up to 18 mm up to 13 mm up to 18 mm

6,000 cycles/h 9,000 cycles/h 9,000 cycles/h 11,000 cycles/h 12,000 cycles/h 13,000 cycles/h 14,000 cycles/h 14,000 cycles/h 16,000 cycles/h 22,000 cycles/h 30,000 cycles/h

16,000 cycles/h 16,000 cycles/h 30,000 cycles/h

Accessories and options Tipping in cards and merchandise samples Automatic loading from rolls and/or bundles Quick Transfer Trolleys New Asir 3: Automatic signature recognition (Bar code and image) Connex for digital workflow with JDF/JMF according to the CIP4 standard Selective binding: Primera 130, PrimaPlus SB, Primera 140, Optima, Tempo 22, Supra In-line/off-line inserting and film wrapping with Onyx/Rubin In-line inserting Integro with Tempo 22, Supra Film and shrink wrapping Cohiba and Fontana automatic palletizer BOGRAMA punching machine together with saddle stitching

Connex Workflow System

1,000 cycles/h

With the Connex workflow system, all Muller Martini machines, from stand-alone machines to complex production lines, can be networked together with the customer’s Management Information System (MIS). New

1,000 cycles/h

Muller Martini Panorama Spring 2010

Softcover Production

Hardcover Production

Newspaper Mailroom Systems

Book-sewing machine Ventura MC

Mailroom technology Mailroom system planning Installation and commissioning Training Production support Machine audit Maintenance

12,000 cycles/h

Integrated book-sewing system VenturaConnect up to 3  12,000 cycles/h

Gathering machines 1571 6,000 cycles/h 3693 8,000 cycles/h 3694 New 8,000 cycles/h 3695 12,000 cycles/h 3696 New 12,000 cycles/h 3681 18,000 cycles/h 3697 18,000 cycles/h Asir 3: Automatic signature recognition (Bar code and image)

Gathering machines 1571/21” 3693-d/24”

6,000 cycles/h 6,000 cycles/h

In-line finishing 3644 Universo stacker delivery BBF Book block feeder VBA Endsheet feeder

6,000 cycles/h 4,200 cycles/h 4,200 cycles/h

Backgluing machine Collibri

4,200 cycles/h

In-line finishing 3644 Universo stacker delivery 1587 Book block feeder 3642 Book block feeder VBA Endsheet feeder, hotmelt or cold emulsion CrissCross delivery

6,000 cycles/h 4,000 cycles/h 8,000 cycles/h 8,000 cycles/h 5,000 cycles/h

Perfect binders AmigoPlus 1,500 cycles/h Pantera 4,000 cycles/h Acoro A5 5,000 cycles/h Acoro A7 7,000 cycles/h Bolero 9,000 cycles/h CoronaCompact CC12 / 24” 12,000 cycles/h Corona C12 / 24” 12,000 cycles/h Corona C15 S / 18” 15,000 cycles/h Corona C15 L / 24” 15,000 cycles/h Corona C18 / 18” 18,000 cycles/h Face trimmer Frontero

6,000 cycles/h

Three-knife trimmers Esprit Merit S Zenith S Orbit

2,000 cycles/h 4,000 cycles/h 7,000 cycles/h 7,200 cycles/h

Counter stackers Uno CB 16 CB 18

16,000 cycles/h 18,000 cycles/h 18,000 cycles/h

Packaging, conveying and material handling Conveying and packaging systems Inserting/film-wrapping line Onyx/Rubin Cohiba and Fontana automatic palletizers

Book block pressing machine RPM roller press 4,200 cycles/h RPM/GPM roller/full-surface pressing machine 4,200 cycles/h TPM drying and roller press 4,200 cycles/h Three-knife trimmer Esprit Merit S

2,000 cycles/h 4,000 cycles/h

Casemakers  BDM Compact BDM Universal BDM Speed

2,700 cycles/h 3,600 cycles/h 5,100 cycles/h

Ribbon inserter Ribbon

3,900 cycles/h

Booklines Diamant MC 35 bookline, consisting of: RHE casing-in line 2,100 cycles/h EP 340 joint forming and pressing machine 2,100 cycles/h Diamant MC 60, bookline consisting of: RHE casing-in line 3,600 cycles/h EP 680 joint forming and pressing machine 3,720 cycles/h Book stackers BLSD flow-through or end stacker Jacketing machine Vesta

Newspaper conveyor systems NewsGrip A Newsveyor Topveyor Buffer and storage systems FlexiRoll Automatic FlexiRoll High-rack storage Inserting systems AlphaLiner SLS3000 ProLiner CoLiner New

18,000 cycles/h 32,000/64,000 cycles/h 45,000 cycles/h 45,000 cycles/h

Packaging TABA automatic top sheet application Ink-jet addressing Robusto Compensating stacker 30,000 cycles/h PrintStack CN 80 Compensating stacker 80,000 cycles/h Listo New Compensating stacker 100,000 cycles/h NewsStack (Compensating stacker) 100,000 cycles/h CombiStack 32,000 cycles/h Packaging lines Bundle distribution Conveying and distribution systems NewsSorter (Bundle conveyor system) 120 bundles/min Trimming NewsTrim III New 40,000/80,000 cycles/h Preciso N rotary trimmer 100,000 cycles/h

3,900 cycles/h

Value added Labeling system PowerWrap film-wrapping system Card gluer ValueLiner New

3,900 cycles/h

Control system MPC Mailroom Production Control

Transport systems Spiral and lay-down element Conveying and packaging systems

www.mullermartini.com Muller Martini Panorama Spring 2010

Let Muller Martini amaze you with a whole range of innovations at Ipex 2010.

Grow with Productivity.

May 18 to 25, 2010 NEC Birmingham Hall 19, Stand C750

High levels of productivity, flexibility and innovation are crucial when it comes to gaining a competitive edge in the market. At Ipex 2010, Muller Martini is exhibiting innovative and highly automated solutions that enable efficient production and can be expanded easily. A fantastic range of innovative products awaits you.

Register at www.mullermartini.com to receive a free admission ticket. The site also contains information about your visit to the exhibition and our exhibition stand.

We look forward to seeing you there!

Increase your Productivity

Müller Martini Marketing AG Untere Brühlstrasse 13 CH-4800 Zofingen, Switzerland Phone +41 (0)62 745 45 75 Fax +41 (0)62 751 55 50 info@mullermartini.com www.mullermartini.com

Visit our stand for a live demonstration on how to boost your productivity. E Expansion of the Primera saddle stitching line at both the low and high end. E The new generation of Presto saddle stitcher. E Further enhancements of the Bolero perfect binder. E Find out more about the latest developments in variable size offset printing.

Grow with digital solutions. As the leading inline finishing specialist, Muller Martini can provide excellent digital printing solutions. Find out how we work in successful partnership with well-known digital printers with a wide range of digital print systems.

Boost your productivity with new services. Ipex sees the launch of a new range of global services from Muller Martini. In future, the range of international services will be standardized and expanded under the label MMServices.