Muller Martini Panorama, 2011, Spring by Polygraphimport Webman

The magazine for Muller Martini customers

Spring 2011

State-of-the-art web offset presses, such as the VSOP from Muller Martini, continue to forge ahead in the food packaging market thanks to their infinite size variability

Editorial

Package Printing: Muller Martini as a System Supplier and Specialist Partner

E After the decade-long domination of flexo and rotogravure printing in the package printing sector, with circulations running into the millions, web offset printing is now making further inroads into this future-oriented market. The benefits of offset printing are quite obvious. In order to be able to efficiently produce smaller print runs, which come about as a result of seasonal sales campaigns, product promotions varying across regions and changes in language, printing houses have to significantly reduce their preprinting costs. If the variety of print jobs and the frequency that the subject changes increases, this will inevitably result in a larger number of printing methods. Compared with flexo and rotogravure printing, these methods are much more cost-effective with web offset processes – not to mention the significantly shorter setup times for offset printing presses. To reinforce their position in this interesting market, Muller Martini acquired the patents for VSOP from Drent Goebel two years ago and has been gradually developing this machine type ever since. Both the VSOP and the Alprinta V have now established themselves in the packaging market. The strengths of the Alprinta V, developed by Muller Martini, lie in label printing; however, the VSOP has a web width of up to 850 mm and a continuous size range of 381–762 mm (15 – 30 inches) and is supplied with almost 80 flexible packaging and cardboard box printing systems, thus ensuring that it remains firmly in the running. This new web offset technology was first introduced around ten years ago. Since then, it has been optimized and is now used in over 100 printing presses worldwide, thereby enabling every type of paper and film product to be manufactured on these hybrid systems. The core of the system – usually between five and eight web offset printing units – is supplemented with two

Dr. Andreas Hitzler, Head of Marketing and Sales, Muller Martini Druckmaschinen GmbH

or three flexo/rotogravure printing units. As a result, the cost-effective offset printing process is able to take advantage of the benefits of flexo printing, such as larger application volumes for lacquer, opaque white and metallic inks. Last October, Muller Martini chose to introduce this sophisticated and well-established technology to over 300 guests at an open house event, providing live demonstrations on the VSOP and Alprinta V (see “Panorama” 3/10). In addition to the machine demonstrations, our partners showcased the manufacturing process involved in producing water bottles decorated with a shrink sleeve, rotating die-cutting and stacks of a pre-printed in-mould-label, as well as the wide range of laminating options with 12-µm PET film, for example. A further process step demonstrated how soup pouches and similar products are manufactured. One of the main highlights that particularly impressed the visitors, who had traveled from all around the world to attend the open house at the Training Center Presses in Maulburg, were the interesting expert presentations. These were an effective way of showcasing the latest developments for the entire value-added chain in the package printing sector. The presentations also served to highlight Muller Martini’s expertise as a system supplier. One of the most highly regarded presentations at our open house event was,

without doubt, the one held by Dr. Stéphane Papilloud. The Packaging Food Safety Group Manager in the Quality & Safety Department at the Nestlé Research Center in Lausanne, Switzerland, used his presentation to emphasize the stringent requirements in the food packaging industry. A few weeks later, Dr. Papilloud held a question-and-answer session with our customer magazine. Read the article on package printing on page 6 of this issue of “Panorama” and find out more about the type of print runs printing houses have to be able to deliver, should they want to work with Nestlé, and the ways of preventing unpleasant incidents. This issue also contains specialists from ink manufacturers SunChemical and Zeller + Gmelin voicing their opinions on the specific challenges they face when using low-migration printing inks (page 10). I hope you enjoy finding out about the endless possibilities that lie in the package printing sector! Yours sincerely

Dr. Andreas Hitzler, Head of Marketing and Sales, Muller Martini Druckmaschinen GmbH Muller Martini Panorama Spring 2011

Contents

Imprint

Volume 26 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

6 “Nestlé views its print suppliers as partners,” says Dr. Stéphane Papilloud of the Nestlé Research Center in a major “Panorama” interview.

16 At the Hunkeler innovationdays event in Lucerne, Muller Martini unveiled its digital printing solution in the shape of the Primera Digital stitcher.

41 The MMservices module MMRemote Online is helping Southern Print optimize the performance of its new Corona C18 perfect binder.

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.

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 2011

Forum Food packaging – UV flexo and offset printing presses on the rise

Printing Presses Läser, Gontenschwil – New Alprinta 74V for roll labels and shrink sleeves Government Printing, Pretoria – Concepta provides world-class security printing

12 14

Digital Solutions Hunkeler innovationdays – Primera Digital opens up new growth opportunities

Open House Bad Mergentheim – Five production runs and four size changes in just 20 minutes

Hardcover Production GGP, Pössneck – In eleven years, the Diamant has produced 125 million books

News

Saddle Stitching Systems Aller Tryk, Copenhagen – Synergies achieved by Using the Supra and PrintRoll Together Nuova Jolly, Rubano – Up to ten job changeovers a day on the Primera C130 Tipolito Moderna, Due Carrare – When the company name is a commitment Halley, Teresina – The Primera E140 as a specialist machine for large-size products

24 26 28 30

Softcover Production Ediouro, Rio de Janeiro – Corona + Frontero = one work step instead of seven JKJ, Falköping – 50% more books than two years ago thanks to the Pantera Printera, Sveta Nedelja – The Acoro is required for frequent changeovers

31 32 34

Newspaper Mailroom Systems UPP, Abu Dhabi – Cards on newspapers are becoming increasingly important

Press Delivery Systems LINUS WITTICH, Herbstein/Herzberg – A press delivery system, made to measure

Services Southern Print, Poole – MMRemote Solution for the new Corona C18 perfect binder

Forum Package Printing

Innovative Technology for Package Printing

VSOP – Variable-Size Offset Printing for Maximum Flexibility The Muller Martini VSOP (Variable Sleeve Offset Printing) web offset printing press is ideal for printing flexible packaging, labels, films and cardboard, thanks to its new design. The sleeve technology allows print sizes to be changed quickly and easily without having to change all of the printing inserts. This is a particular advantage, and particularly cost-effective, for print lengths that change frequently.

To change the printing unit on VSOP printing presses, only two sleeves need to be changed without tools.

E The Muller Martini VSOP web offset printing press is a total solution for a wide variety of fields of application in high-quality package printing. Thanks to simple and rapid size changes, the machine allows a high level of flexibility in production. Handy Sleeves The plate and rubber blanket cylinders in the VSOP printing unit are designed as handy sleeves. Due to their particularly low weight, these sleeves are very ergonomic to handle. They can be changed quickly and easily, without having to change all of the printing inserts. This means that the 4

VSOP printing unit is infinitely variable for all print image lengths. A job and size change can be completed in a matter of minutes. Furthermore, the sleeve change can be carried out without tools and on the operating side, ensuring a high level of user-friendliness. To maximize machine productivity, every print job can be prepared offline and while the machine is running. A quick changeover system, including automatic pre-adjustment, automatically enters the settings. The machine settings can be stored in an integrated database so that jobs can be printed again at any time.

First-Class Print Quality The VSOP printing press also has an efficient inking system with tempered vibrator rollers. Using this system, the VSOP printing units deliver the first-class printing quality needed to meet the tough requirements of the package printing market. Thanks to standardization in offset printing technology and to the high level of automation, precise color reproduction is also guaranteed – of great importance for branded products. The speeds of the impression, rubber blanket and printing plate cylinders can be altered individually at each printing unit, Muller Martini Panorama Spring 2011

Forum Package Printing

Low-Migration Ink Systems for Package Printing

Quicker and More Cost-Effective Production with UV Offset Printing The vast majority of food packaging is still being printed using rotogravure printing and flexo solvents. But modern UV-flexo and offset printing presses – such as the VSOP from Muller Martini – with their infinite size variability and new low-migration ink systems are continuing to make headway.

E For decades, high volume runs dominated package printing – on a scale of hundreds of millions of copies per job. Rotogravure and solvent flexo printing are ideally suited for jobs on this scale. But this has not been the case with more recent developments – key points: seasonal sales activities, personalized products, language changes, bar codes, numbering – which increasingly favor smaller and smaller print runs, resulting in an increase in variety and frequent layout changes. One of the most important consequences of these constantly shrinking batches: to ensure that small print runs can also be produced efficiently, preprinting costs must be significantly reduced. 10

Many Specialist Applications This is where web offset printing comes into its own. Not only are printing methods substantially cheaper with web offset, but in comparison to rotogravure and flexo printing, setup times for the machines are also significantly reduced. Result: UV offset printing allows for quicker and more cost-effective production. In addition, thanks to modern printing presses, offset/ flexo and/or offset/rotogravure combinations allow for a large number of special applications, using textures and matte/gloss effects. This development, however, has only been made possible by the new low-migration ink systems for package printing. Be-

cause, for the printer, problems with solvents and related costs – considering the significant minimization of the price difference between UV and solvent inks – are not a substantial factor in the high rate of growth in energy-cured ink systems. Winning Over the Skeptics “In fact,” says Andreas Rascher, Product Manager at printing ink manufacturer Zeller-Gmelin in Eislingen/Fils, Germany, “for a long time many market and opinion leaders were skeptical about UV. But these attitudes have changed, because UV is the best controlled and supervised ink system on the market. And I am confident of the fact that, in the future, conventional ink Muller Martini Panorama Spring 2011

Printing Presses

“Film Packaging Is the Future” For the first time ever, cardboard packaging and (wet-adhesive) label specialist printing house Läser AG in the Swiss town of Gontenschwil has opted for a web-offset printing press in the form of an infinitely size-variable Alprinta 74V from Muller Martini. As a result, the company can now produce label rolls (wrap-around) and shrink sleeves. “Film packaging is the future,” says company owner Jürg Läser confidently.

E Until mid-way through this year, the Läser AG graphics company, one of the leading packaging producers in Switzerland, was printing all manner of labels and packaging for the (largely local) food, cosmetics and tobacco industry on sheetfed presses. However, the situation changed back in June when the traditional company commissioned a web-offset printing press for the first time in its 58-year history. “Significantly Faster Processing Times” Company owner, director and chairman of the board Jürg Läser explains the decision to opt for the new hybrid solution with its 12

offset and flexo printing units, saying: “It allows us to print on plastic as well as paper, and I am confident that film packaging is the future.” Läser AG can now also print web-offset products such as wrap-around labels and shrink-sleeves. The company opted for the Alprinta 74V after a long evaluation period. According to Jürg Läser, the fact that Muller Martini has an excellent market reputation was of course another deciding factor. Läser explains that the 740-mm. wide version was installed as more and more products are being stored in the form of rolls rather than sheets – and this applies in particular to medium and large orders. “Our processing times are much shorter now we are using

the web-offset rather than the sheet-fed offset,” says Jürg Läser. Rapid Finishing Processes Another important reason for choosing the Alprinta was the fact that the finishing equipment from Muller Martini, consisting of a Q74 sheeter and Uniplus 750 stacker, provides an optimum finishing workflow. “With this equipment, we have an almost in-line process which gives us a much faster workflow than we achieved with the sheet-fed offset and subsequent cutting and stacking processes,” Jürg Läser explains. In addition to six offset printing units, the new Alprinta 74V at the Läser premisMuller Martini Panorama Spring 2011

1 Jürg Läser (right) – company owner, director and chairman of the board: “When it comes to medium and large orders, our processing times are much shorter now we are using the web-offset rather than the sheet-fed offset.” Richard Hofer (left) – Sales manager at Muller Martini Switzerland. 2 The infinitely size-variable Alprinta 74V from Muller Martini is the first web-offset printing press to be commissioned by Läser AG. 3 The Q74 sheeter and Uniplus 750 stacker provide an optimum finishing workflow.

es features an inkjet system and two flexo printing units. These units are used to create special effects with gold and silver, and for orders requiring opaque white lacquer and dispersion coatings. The two flexo printing units can be used with UV, water and solvent-based printing inks and lacquers. All Bases Covered Well-finished products, which were often die cut for the foodstuffs industry, are very much a specialty of the Läser printing house. These products include peel-off labels, which are often produced using special materials, such as hotmelt and paper/ plastic compounds. Muller Martini Panorama Spring 2011

These removable, self-sticking labels were designed as an optional extra for product applications in which it is necessary to put a lot of text on one container. These labels can also be supplied with variable data, such as alphanumeric prize codes, as required. “Thanks to the Alprinta 74V, we can now provide almost all the label procedures required in the labeling segment and offer them from a single source,” says Jürg Läser. Replacing Cylinders Is Quick and Easy For Jürg Läser, there is no doubt that package, label and shrink-sleeve printing will be a growing sector in years to come due to the importance of the consumer goods in-

dustry. Läser also believes that film printing, and therefore web-offset printing, will become increasingly important: “Web-offset printing is the future because the resulting product is more convenient and easier for the user to handle.” The company director is also just as confident about the company’s future: “I believe that we will continue to enjoy consistent and stable growth. To stand out and be successful in this influential market, you first need a varied product range, followed by a wide customer base.” 

www.laeser.com 13

Digital Solutions

Hunkeler innovationdays: Primera Digital Attracts a Host of Visitors to the Muller Martini Stand Awe-struck customers, impressive demonstrations and interesting shop talk about high-performance production solutions for digital printing – the Primera Digital saddle-stitching system at Muller Martini's stand really captivated the crowds over the entire Hunkeler innovationdays event in Lucerne, Switzerland. ers!) to reach their target groups more successfully. This shift presents a number of challenges throughout the entire process – for printing, for the finishing process and for the workflow. And the more powerful digital printing systems become, the more challenging the finishing process will be.

E Muller Martini showcased a powerful digital printing production solution in Lucerne. The Primera Digital saddle-stitching system was promoted with the slogan “Grow with Digital Solutions.” This industrial manufacturing solution opens up the market for full-color digitally printed magazines, periodicals and brochures. A Wealth of New Opportunities Larger web widths and higher speeds, greater productivity, full color and a wider range of printable paper varieties – this high-output inkjet digital printing method 16

was until recently used mainly in transaction and mailing printing. However, following its use for hardcover and softcover publications, it is now offering a wealth of new opportunities for saddle-stitched printed products. Run sizes for magazines, periodicals and brochures are currently falling but, at the same time, product variety is on the increase. Processing times are also getting shorter and shorter. In addition, personalization of saddle-stitched products will increase dramatically in the future, as personalized products allow publishers (and advertis-

Muller Martini Panorama Spring 2011



Muller Martini used the Hunkeler innovationdays event in Lucerne as a forum to showcase the Primera Digital saddle-stitching system – a high-performance solution for stitched products in the field of digital printing.

Live Presentation of Three Different Demonstration Products In view of this background, Muller Martini used the Hunkeler innovationdays event in Lucerne as a forum to demonstrate the advantages of a compact yet powerful solution for saddle-stitched, digitally printed products. The solution demonstrated features an unwind unit and a sheeter from Hunkeler and a Primera Digital saddlestitching system – this system offers a new and innovative processing folder with gathering station, as well as highly automated technology from the Primera modular system with a cover folder feeder, stitching machine and three-knife trimmer. A variety of products were produced live, non-stop and on-the-fly. A copy-specific cover was, on request, fed in and applied to the relevant product. “The configuration on show at Hunkeler innovationdays, with loading from the pre-printed roll, is just one possible application,” says Dragan Volic, Head of Marketing for Saddle-Stitching Systems and Digital Solutions at Muller Martini. “The system really comes into its own when finishing equipment from several printing presses needs to be loaded or when these presses are also used for other processes. Of course, the Primera Digital can also be used as an in-line solution, as it can cope with the high output levels of high-speed digital printing presses.”

Photos of highlights from the Hunkeler innovationdays event

Muller Martiniâ&#x20AC;&#x192; Panorama Spring 2011

Digital Solutions

Primera Digital – Suitable for Both Digital and Conventional Production The Primera Saddle-Stitching System is ideally suited for digital solutions, as it offers the highest possible levels of automation and process reliability and features the modular system that is already familiar from conventional production methods. This system is, and will continue to be, indispensable for digital inkjet printing. The Primera Digital can also be fitted and loaded with signature feeders for conventional applications. All of the configurations that are possible with the Primera modular system are also possible using the Primera Digital. As a result, the system can be optimally used for both digital and conventional production methods. It is even possible to manufacture combined products, using digital and offset printing. To allow further finishing of the products, the line can be enhanced with additional elements such as inserting, filmwrapping and punching machines or a bundle-building system.

High Investment Protection “Customers who decide to use a Primera for conventional finishing can count on the fact that this system can subsequently be integrated into a digital printing line at any time,” says Dragan Volic. “The modular design of Muller Martini systems thus supports elegant extension options. It provides customers with a secure investment by fulfilling both their current digital printing requirements and those of the future.” Integration in the SigmaLine The Primera Digital can also be integrated into a Muller Martini SigmaLine complete system. The SigmaLine networks all processes, from the prepress specifications through to digital printing and finishing, in one complete system, enabling fully automated production in a single operation, from the roll to the finished printed product. This consistent linking of all subprocesses is the key to producing short runs extremely quickly and efficiently. Using this digital complete system, customers can reap the full benefit of Muller

Martini's extensive experience and expertise as the global market leader for in-line finishing processes in all areas of print finishing. This is true not only for saddle stitching, but also for softcover and hardcover solutions – powerful perfect binders such as the Pantera and the Acoro or the Diamant MC bookline can also be integrated into the complete system. Hybrid Solutions Also Possible This means that, using the SigmaLine, hybrid saddle-stitching/softcover or softcover/hardcover solutions are also possible. “Muller Martini increases the options for traditional finishing,” emphasizes Dragan Volic, “and this means that digital printing can achieve its full potential. We are offering the graphics industry new growth op portunities.”

www.mullermartini.com www.innovationdays.ch

Customer Impressions from Lucerne – “Muller Martini Creates the Market” “Breaking New Frontiers” Bill Graushar, Vice President of Post Press Technology at Quad Graphics in Sussex, WI (USA): “What I saw at the Muller Martini stand can be filed under the category of 'breaking new frontiers’. The new possibilities that have been opened up in the field of digital printing are definitely a hot topic, and now Muller Martini is truly showing us what it’s all about. No other company has developed a system to rival this one. Muller Martini creates the market. For digital printing, we use systems that speed up production throughout the finishing process and reduce the processing times for each job.”

“The Perfect Combination” Steve Ellithorpe, Operation Manager at O’Neill Data Driven in Los Angeles, CA (USA): “Digital printing and finishing are moving increasingly closer to becoming a single process. The two production processes have become more closely integrated than ever before, as I discovered on my first visit to Hunkeler innovationdays. Reducing the time slot required for the production process is of great importance to us, as this would result in lower costs. The Primera Digital from Muller Martini is the perfect combination of traditional finishing methods and new digital technology.”

“At a Crossroads” Alex Chan, Chairman of Iciclegroup, Global Print Management, Hong Kong (China): “I have been in the graphic design industry for almost 40 years, have known Muller Martini for a similar amount of time and have observed that printing production systems are at a crossroads. Digital printing is the future and the key theme will be 'on demand'. Customers only want to have as many products printed as they need. And this includes the relevant finishing solutions. We identified this development at an early stage and, as a result, started using digital printing in 2002.”

“The Barriers Have Fallen” Roger Schenk, Head of the Printing House at Stämpfli Publikationen AG, Berne (Switzerland): “I was overwhelmed by what was on offer in Lucerne. What amazed me in particular was the extent to which digital printing is linked to finishing. The barriers between manufacturers of printing presses and finishing systems have definitely fallen. Fully integrated solutions, such as those offered by Muller Martini, increasingly enable graphic design companies to offer customers a complete service and keep the entire value-added chain in-house.”

Muller Martini Panorama Spring 2011

Muller Martini Open House in Bad Mergentheim

Five Different Productions and Four Size Changes in Just 20 Minutes! To celebrate the tenth birthday of the successful Diamant bookline, Muller Martini Book Technology showcased the new Diamant MC hybrid bookline as part of an open house event in Bad Mergentheim. An impressive presentation saw all of the previous records for size changeovers broken.

E The Diamant was launched on the market ten years ago. Since then, the bookline has always been at least two steps ahead of the competition. Several new versions of the Diamant have been developed and consistently aligned to market requirements. The Diamant MC digital has been commercially available for some time now, featuring a sequential changeover function and a design oriented toward personalized books such as photo albums. The Diamant MC hybrid combines all of the features of the classic Diamant MC with those of the Diamant MC digital, making it ideal for the manufacture of a wide range of books in both low and high-volume runs, as well as for the production of personalized books. Ultra-Fast Changeovers At the open house demonstrations, five different books – each with a headband, and four with a straight spine and one with a rounded spine – were manufactured one after the other in just 20 minutes. The sizMuller Martini Panorama Spring 2011

es of the runs varied between 60 and 100 copies. On three different occasions, the changeover only took around one minute, whilst one changeover took around five minutes. Some 200 guests had traveled from 24 different countries to see this demonstration and were suitably impressed. In another presentation, 30 books of varying thicknesses were produced. Once the last of the ten book blocks had left each station, the Diamant MC hybrid was able to adjust each station sequentially. The guests were fascinated to see the different-sized stacks of 10 books coming out of the book stacker in quick succession. Consistent Automation The engineers at Muller Martini Book Technology have been consistently developing the stations to minimize time lost when making a changeover. Thanks to the tandem stations, operators are now able to switch between two headbanding stations very quickly. Another highlight of the sys-

Around 200 guests from 24 different countries traveled to Bad Mergentheim for the Muller Martini open house event.

tem is the innovative covering station, which facilitates optimum production logistics. This consistent automation ensures that short-run productions can be implemented efficiently. Imre Újvári, Production Manager at Reálszisztéma Dabasi Nyomda in Hungary, shares the same view as many of our customers: “These demonstrations showed us that the Diamant MC hybrid offers extremely fast changeover times with very little production waste. We have come away with new ideas for methods and solutions to improve and speed up the way in which  we serve our customers.” Open house event photo gallery: www.mullermartini.com 19

Hardcover Production

In Eleven Years Diamant at GGP Media Produced 125 Million Books Since the very first Diamant bookline ever delivered was installed at GGP Media in Pössneck (Germany) eleven years ago, it has been producing many books of the highest quality day in and day out – just as reliably today as on the first day.

E At the beginning of 2000, VBF Buchtechnologie, predecessor to Müller Martini Buchtechnologie, delivered the very first Diamant ever: to GGP Media in Pössneck. The innovations that the bookline presented in comparison to its predecessor, model BL 500 were enormous. It featured an entirely new drive concept and offered an increased machine speed, shorter setup times, an extended format range and simpler operation. The mechanical shaft had been replaced by an electronic control system. More than twenty servomotors were now automatically adjusting what previously had to be set by hand. 20

Perfect “cooperation partner” This had been a huge step for the machine operators at GGP Media. Not only did they quickly get used to the new bookline, they were also thrilled about the possibilities the Diamant offered. Uwe Schulz, Head of Production and Engineering at GGP Media remembers: „As soon as the bookline was installed, we began producing – without as much as a trace of startup difficulties.“ This had been a huge step for the machine operators at GGP Media. Not only did they quickly get used to the new bookline, they were also thrilled about the possibilities the Diamant offered. Uwe Schulz,

Head of Production and Engineering at GGP Media remembers: „As soon as the bookline was installed, we began producing – without as much as a trace of startup difficulties.“ Another almost “overnight” job were the books by Le Clézio, the unexpected Nobel Prize winner of 2008, which GGP produced and delivered to the book retailers. Each time, the Diamant proved to be the perfect “cooperation partner”. Perfect book spine rounding Over the last ten years, it has handled everything from large to small printruns, Muller Martini Panorama Spring 2011

1 Ten years ago or today: Uwe Schulz (left) and Heiko Heinemann are happy about their investment in the Diamant. More than 125 million books have already been produced with it.

2 Over a heating conveyor, the bookblocks are run into this first Diamant bookline, married with their cases and expelled as high-quality books.

most of them ranging between 1500 and 4000 copies. The Diamant runs and runs and runs. Heiko Heinemann, Head of Engineering, is more than satisfied with the reliability of the Diamant: “We had not even one recurrent repair.” And Uwe Schulz adds that in the last ten years there hasn’t really been any notable increase in repair costs. Back then, the perfect book spine rounding achieved with the Diamant had been an important pro investment criterion. The effective double backing feature makes sure that the spine maintains its rounding. The books produced are not only of excellent Muller Martini Panorama Spring 2011

3 The machine operators Ralf Lindig, Mandy Ludwig and Frank Blumenstein (from right to left) handle the hardcover production line from three-knife trimmer to jacketing machine.

quality; the Diamant also realizes a great variety of book shapes and sizes. Excellent book quality At regular intervals, the ten-year-old Diamant finishes books with flaps and integral covers, just to name a few. Bookbinder Ralf Lindig, who has been operating the Diamant for the last decade, knows the bookline and all its possibilities like the back of his hand. He is proud of “his machine” producing excellent book quality. The success with the Diamant bookline also depends on those working with it. At GGP Media, only skilled operators handle

the machines. Since 1992, the Bertelsmann subsidiary has been training three to five bookbinders a year. Among all the sectors, the well-established Pössneck company schools about fifty trainees. Excellently trained and motivated staff and the proper machine pool are the best assets with which to warrant future growth of the company. Therefore, the three traditional GGP Media pillars – expert consultancy, adherence to delivery dates and flexibility – are assured well into the future. 

www.ggp-media.de 21

Mayor of Bremen Jens Böhrnsen (center) along with BIB Managing Director Aram Aritim (right) and his family.

How Bremer Industrie Buchbinderei Even Impressed Mayor Jens Böhrnsen With 38 employees, Bremer Industrie Buchbinderei GmbH is an outstanding example of how people with a migrant background can become successful entrepreneurs. In 22 years, Turkish-born Managing Director Aram Aritim has grown BIB into a well-known, competent and efficient print fin-

ishing partner within the post press industry. His company works for printing houses right across Germany. The company opts for Muller Martini systems for its print finishing processes, using two PrimaPlus Amrys and Prima saddle stitchers as well as a Trendbinder perfect binder.

The BIB success story had not gone unnoticed by the mayor of Bremen, Jens Böhrnsen. That’s why Böhrnsen recently decided to pay Aram Aritim and his work force a visit. “We need to highlight success stories like these as good examples, particularly for young people from migrant back-

grounds,” said Böhrnsen. Entrepreneurs like Aram Aritim could “become real trailblazers for integration” if they could relate their experiences to young people directly.

The World’s Largest Qur’an Printer Once Again Puts its Trust in Two Diamant Booklines

Nr1 Trykk: New Systems from Muller Martini to Take Care of Increasing Insert Volumes

With an annual printed total of 10 million copies, the King Fahd Complex for the Printing of the Holy Qur’an is the world’s largest printer of the Qur’an. Starting this summer, the holy Islamic text will be produced in the Saudi Arabian city of Medina on two Diamant MC 60 booklines from Muller Martini. “At our company, our keyword is unique,” says Dr. Mohammad Salim Al-Oufi, General Secretary at King Fahd Complex. “We strive to be unique when it comes to our books, so this is why we set high quality standards at all production levels. It is for this reason that we also want to be unique when it comes to our production systems.” Both Diamant booklines at King Fahd Complex, which employs a team of 1500 people, will be put into operation this summer and feature the same configuration. In addition to the Diamant casing-in line, both

Nr1 Trykk produces no fewer than 18 daily newspapers at its plant in Lillestrøm, for both the in-house publishing company and external publishers. The leading Norwegian newspaper publisher has been relying on Muller Martini solutions in its mailroom for many years now. Of the three NewsLiner inserting systems currently used by the company, the oldest, which was commissioned in 1996, is being replaced by a new NewsLiner A system this summer. Summer 2011 will also see Nr1 Trykk commission another NewsStitch stitching unit, plus another NewsTrim III trimming line. “We decided to go ahead with this investment because our insert volume has continued to rise in recent years,” says Operating Director Morten Kringler. With the new machines, we will not only be boosting our capacity, but also creating a back-up solution for our stitching and trimming processes.”

Dr. Mohammad Al-Oufi (right), General Secretary at King Fahd Complex, and Bernhard Schmid (left), member of the Muller Martini corporate management, seal the deal for the purchase of two Diamant MC 60 booklines. Center: René Thüler, Muller Martini Sales Manager for the Middle East.

machines comprise a Collibri gluing-off machine, a Ribbon bookmark ribboning machine, a Merit S three-knife trimmer and a BLSD 650 book stacker.

Nr1 Trykk has been relying on NewsLiner newspaper inserting systems from Muller Martini for many years now.

Nr1 Trykk also prints magazines and publicity brochures on its rotary newspaper press, and these products are then stitched by the NewsStitch system and trimmed by the NewsTrim III system. “This approach allows us to increase utilization of our printing presses and mailroom,” explains Morten Kringler.

For Saddle Stitchers and Perfect Binders: Pneumatic Bundle Clamp with Turning Device A new turning clamp from Muller Martini permits easier and more efficient loading of the Streamfeeder on saddle stitchers and perfect binders. The motor-driven turning unit guarantees control when turning the clamps. The clamp is opened and closed by two pneumatic cylinders. Thanks to an innovative drive system, the Muller Martini Panorama Spring 2011

turning clamp can also be used for large size ranges. It can be used to process bundles in sizes A5 to A3 and between 665 mm and 1200 mm. Operation is highly ergonomic without impacting forces on the operator or bundles, which remain small. Separate elements for defining motions and for acti-

vating the turns, allow work to be completed safely and comfortably. The operating principles and drive technology provide optimal anti-trap protection if the turning clamp is accidentally blocked.

Thanks to an innovative drive system, the ergonomic turning clamp can also be used for large size ranges.

Saddle Stitching Systems

The Primera C130 Shows Its Strength with Ten Job Changeovers Per Day Grafiche Nuova Jolly, based in Rubano, Northern Italy, is benefiting from its new Primera C130 saddle stitcher twice over, recording a higher net output of printed products produced in-house and receiving more finishing orders from other printing houses.

1 E On average, Grafiche Nuova Jolly produces 10,000 copies of its printed and stitched products on nine sheet-fed offset machines. However, it is not uncommon for this full-service graphic design company to process orders of just 1000 copies. This means the saddle stitchers must be changed over frequently. “On average, we complete around ten job changeovers per day,” says owner Ivano Bastianello, who founded the company in 1982 with one employee and now employs 37 people.

1 Ivano Bastianello, founder and owner of Grafiche Nuova Jolly (center): “With the new Primera C130 saddle stitcher, we have considerably increased our profitability.” On the right is machine operator Luca Zanella, and on the left is Francesco Bertuzzo of Muller Martini Italy. 2 Grafiche Nuova Jolly now produces high-volume runs of up to 300,000 copies on the new Primera C130 saddle stitcher in two-up production. 3 The new Acoro A5 perfect binding line must also be changed over several times a day.

Two-Up Production for High-Volume Runs The frequent job changeovers are one reason why Grafiche Nuova Jolly invested in a 26

Muller Martini Panorama Spring 2011

new Primera C130 saddle stitcher last summer as a replacement for its Bravo T, which was put into operation in 1997. The second reason was that Grafiche Nuova Jolly sometimes also receives large orders of up to 300,000 copies. “And, unlike before, we can now produce these orders using twoup production,” says Ivano Bastianello. “In doing so, we have considerably increased our profitability. By using fewer man hours on the machine, we have achieved a significantly higher net output at a lower cost.” Increase in Contract Work There is another advantage of using the new Primera C130 with four feeders, cover feeder and Perfetto Amrys stacker: as the printed products can now be stitched in-house much more quickly, Grafiche Nuova Jolly has freed up capacity to accept orders from other printing houses. “This is important for us, particularly in these difficult economic times when margins are under pressure,” emphasizes Ivano Bastaniello. Contract work now makes up one third of the company's volume in its finishing department, which now includes

2 Muller Martini Panorama Spring 2011

a second saddle stitcher from Muller Martini to complement the Prima, which was installed eleven years ago. Aside from its high net output (“we often work close to maximum speed”) and fast Make Ready system (“it is very easy to operate”), Ivano Bastaniello is also impressed with the high level of reliability offered by the Primera C130. “Our customers demand quality products, and so far we have not received a single complaint.” Acoro A5 for Perfect Binding According to the company director, the same is also true of the Acoro A5, which was commissioned a few months before the Primera C130. The new perfect binder line, which features a 16-station gathering machine and Merit S three-knife trimmer and replaced a Starbinder from 1993, must be changed over a similar number of times as the saddle stitcher. Although print runs for products from the sheet-fed offset machines are around 5000 to 7000 copies, runs can go as low as 500 for threadsewn products, which make up around 40% of the company's softcover volume

and for which the book blocks are produced on the gathering machine. And runs for products that are produced using digital printing processes are often just 150 copies. “This means, of course, that it is hugely important that the perfect binder can be changed over quickly,” says Ivano Bastaniello. 

www.nuova-jolly.it

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Saddle Stitching Systems

The Moderna Name Is a Commitment It's all in the name: Within just a short space of time, Tipolito Moderna in Due Carrare, Italy, has invested in a new eight-color machine and a Primera C130 saddle stitcher from Muller Martini to automate the finishing process for its additional print volume.

E “Prices and margins are on the way down, but our customers still expect the same high quality within increasingly tight time frames,” says Pierluigi Nucibella, one of the three co-owners of Tipolito Moderna Industria Grafica. “The only way to respond to these developments,” he maintains, “is to use highly automated, state-of-the-art machines.”

New Eight-Color Printing Press And this was no sooner said than done. Within just a few weeks in the summer of last year, Tipolito Moderna put a new eightcolor Mitsubishi Diamond V3000 TP into operation (the first of its kind in Italy), along with a Primera C130 saddle stitcher from Muller Martini to cope with the considerable print volume during the company’s

finishing processes. The new Primera replaced a 335 saddle stitcher installed in 1995. “We can look back on a partnership with Muller Martini that has spanned two decades,” says Davide Volpin who, along with his father Franco and Pierluigi Nucibella, is co-owner of the company that was established in Padua in 1979. “That's why it quickly became clear to us that another

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Muller Martini Panorama Spring 2011

1 Pierluigi Nucibella, co-owner of Tipolito Moderna Industria Grafica (center): “For me, the Primera C130 is the ideal entry-level machine for industrial production.” On the left is co-owner Davide Volpin, on the right is Francesco Bertuzzo of Muller Martini Italy. 2 Quickly to grips with the new Primera C130 saddle stitcher: machine operator Michele C ozma.

Muller Martini solution was the best option.” Impressive Tests in Switzerland The company eventually chose a Primera C130 on the basis of impressive test results at the Muller Martini Training Center in Oftringen, Switzerland. “We tested various grammages, covers and sizes as well as two-up production,” recalls Pierluigi Nucibella. “And we were really impressed by the high production speeds, short setup times and the excellent quality of the stitched products. For me, the Primera C130 is the ideal entry-level machine for industrial production.” Large Number of Repeat Jobs There was one other aspect to consider: Tipolito Moderna Industria Grafica, which moved into a brand new production facility in Due Carrare in 2007, and employs a staff of 20, produces a range of weekly magazines in various sizes and circulations, in addition to local magazines and standard commercial work. Muller Martini Panorama Spring 2011

“It is therefore very handy if we can use the touchscreen to save individual production data for our periodicals and then call up the data whenever it is needed,” says Davide Volpin. Although you need a certain level of technological expertise to operate the new saddle stitcher, our machine operators have got to grips without any problems.”

ued to use a second saddle stitcher from Muller Martini in the shape of a Presto. “We normally produce the smaller runs on the Presto and the larger ones on the Primera,” says Pierluigi Nucibella. “Or if we are working to tight deadlines, we use both machines to work on the same job. The new Primera C130 has significantly improved our levels of flexibility.” 

Gathering and Cutting Without titching S Tipolito Moderna, whose customers are predominantly based in Northern Italy, prints not only magazines but also advertising material. The latter is also produced on the new Primera C130 — but with no stitching process! “We gather the signatures on the chain and they are then run into the three-knife trimmer with no staples,” says Davide Volpin. After that they are either issued in supermarkets or filmwrapped and sent out to mailboxes. Alongside the new Primera C130 with four feeders, cover feeder and Perfetto Amrys stacker, Tipolito Moderna has contin-

www.tipolitomoderna.com 29

Saddle Stitching Systems

Halley’s New Primera E140 Works Its Magic on Large-Size Products Demand for large-size products is increasing significantly, so Halley Gráfica e Editora in Teresina in north-east Brazil has invested in a new Primera E140 from Muller Martini – the first saddle stitcher of this type in Brazil.

Director Espedito Moreira Sobrinho (left) together with Ronaldo Dias (Sales Manager at Muller Martini Brazil) in front of the new Primera E140 saddle stitcher belonging to Halley Gráfica e Editora in Brazil.

E With the help of the Primera E140 that was commissioned a year and a half ago, Halley Gráfica e Editora (founded in 1993) stitches magazines, advertising supplements, catalogs, newsletters and a whole host of other commercial items – with a particular focus on large-size products. “Order volumes within this product segment have continued to increase since we commissioned the new saddle stitcher,” explains the director of Halley, Espedito Moreira Sobrinho, with obvious satisfaction. “Simple Operation” In addition to the high production speed, the Halley director is particularly pleased with the automatic settings: “The high level of automation on the Primera simplifies 30

operation and allows us to make rapid size changes and create products of outstanding quality. This is why our machine operators really enjoy working on the Primera E140; they look after all the maintenance work too.” Before commissioning the new Primera line, which comprises six feeders, a cover feeder, a three-knife trimmer, and a Perfetto stacker, Halley used a Presto saddle stitcher from Muller Martini for production. Halley, which employs a staff of around 200, has also been home to another Muller Martini creation since 2008 – a Pantera perfect binder. A Stronger Market, but… With its hugely varied product range, including periodicals, catalogs, pamphlets,

brochures, manuals, calendars, posters, and cardboard boxes, Halley is able to serve the entire Brazilian market. According to Espedito Moreira Sobrinho, this market is incredibly dynamic, but also very challenging: “The market for graphic products in Brazil is actually very strong, but the competition is becoming even stronger. To survive this aggressive price war, we increasingly have to invest in automatic sys tems.” www.halleysa.com.br Muller Martini Panorama Spring 2011

Softcover Production

The Corona and Frontero Systems Help Ediouro Replace Seven Operations with Just One With the help of a Corona Compact CC12 and a Frontero front trimmer from Muller Martini, Ediouro Gráfica in the Brazilian city of Rio de Janeiro can now produce brochures with flaps in-line with one operation, making production a much more economical affair. E Ediouro Gráfica, the largest printing house in Rio, produces books and magazines in various sizes with circulations of between 5000 and 1 million copies; several of these products are brochures with flaps. Before commissioning the Corona Compact CC12 and the Frontero, Ediouro used no fewer than seven off-line operations to produce these products. Today, the entire process is completed in-line on just two machines. “With these two systems, we can produce books twice as fast as we used to,” says Mauro Jorge Melli Carvalho Jr. “Important Cost Savings” The two Muller Martini systems have also completely satisfied the Industry Manager’s expectations regarding production

speed, job changes, quality and reliability. “The great thing about the Corona Compact is its high level of efficiency and automation. This means we benefit from greater profitability and significant cost savings,” explains Mauro Melli. “Another huge advantage of our new perfect binder is that it is easy to operate: As the machine operators were trained in-house by Muller Martini Brazil, the perfect binding line has been running smoothly ever since it was commissioned.” Ediouro Gráfica was founded as early as 1939, but only separated from its parent organization (the publishing company) ten years ago. The 60 employees at the printing house, who are employed on a threeshift rotation, originally produced books and magazines exclusively for the in-house

publishing company. Today, however, 70% of production is for external clients, most of which are based in Rio. Recovery after Stagnation Following the stagnation of the Brazilian economy in 2009, the graphics industry has enjoyed a recovery over the past year – not least thanks to strong economic growth and a rise of 7.5% in the country’s GDP. However, according to Mauro Melli, “his” industry currently finds itself in a period of transition due to digital competitors such as the Ebook and iPad. “This transition process is of course happening slowly and I’m certain that both media types will continue to co exist for a long time to come.”  www.ediourografica.com.br

Mauro Jorge Melli Carvalho Jr. (left), Industry Manager at Ediouro Gráfica: “Today, we produce books twice as fast as before.” Right: José Paulo de Sousa, Sales Manager at Muller Martini Brazil.

Muller Martini Panorama Spring 2011

Softcover Production

Significant Increase in Orders on Hand Even in Tough Times Despite the stagnant economy, JKJ Bokbinderi AB from Falköping in Sweden is currently producing some 50% more softcover products than it did two years ago – with the same number of staff. This impressive performance is made possible by the new Pantera perfect binder from Muller Martini.

E Prior to commissioning the Pantera, JKJ Bokbinderi was producing around 3.5 million softcover products each year, using a second-hand Muller Martini Monobloc perfect binder that was purchased in 2001 to replace a Pony system. Since the Pantera was installed just under two years ago, annual production output has increased to over five million copies without any change in head-

count, which is something of an achievement in a turbulent economic climate. Jimmy and Johan Ahlrik, two brothers who founded this family business with their father Jan-Åke Ahlrik in 1993, proudly reveal that: “While other companies in Sweden are reporting declining production figures, we have managed to generate an increase in orders on hand despite these tough times.”

Most Substantial Investment in 17 Years As important as the total output of brochures, catalogs, books and some periodically published magazines is to the company, that is just one facet of this machinery investment, which is the most significant in the company's 17-year history. As well as increasing total output, perfect binding,

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2 thread sewing and fold specialist JKJ has boosted the number of titles it produces (from 300 to 400), increased its customer base (which covers an area of some 150 kilometers) and, more importantly, gained greater flexibility. Reliability and flexibility are particularly important to JKJ; the former because there is no second perfect binder to fall back on,

1 Brothers Jimmy (center) and Johan Ahlrik (left) run family business JKJ Bokbinderi AB in Falköping. On the right is Hans Lilja, Sales Representative for Muller Martini Nordic. 2 The Pantera perfect binder was the most significant machinery investment in JKJ’s 17-year history.

and the latter because the company and its staff of ten cover a broad range of production runs – producing anything from 500 to 300,000 copies, with the average for each job being 10,000 copies. “This means we may need to change over the perfect binding line up to six times each day,” stresses Johan Ahlrik. “And it goes without saying that the process is eminently faster with the user-friendly Pantera than it was with the predecessor model.” The quick setup time really comes into its own if a customer is keen to see a sample before production gets underway. “In the past, meeting requests like this involved considerable effort,” says Jimmy Ahlrik. Thinner than the Machine ‘Permits’ With the current setup, JKJ can also ensure that it is able to fulfill any special customer requirement, as the Pantera can tackle even the most unusual of requests. For example: JKJ recently produced a run of 200,000 copies of a 20-page, 1.6-mm thick brochure for a university, despite the fact that the Pantera is actually designed to accommodate a minimum product thickness of 2 mm. The thickest book produced to date, a product catalog with a run of 15,000 copies, measured 40 mm. In addition, JKJ has also produced a leather-bound booklet for a Swedish automotive company, with a smooth workflow from gathering machine to perfect binder. Machinery experts Jimmy and Johan Ahlrik attended a demonstration of similar

Muller Martini Panorama Spring 2011

production processes at a Muller Martini plant and were impressed by what they saw. “After that we were in no doubt that the Pantera was the right machine for our needs,” they said. And it was not just the perfect binder itself (with its book block feeder, handfeeding station, Esprit threeknife trimmer and CB 16 counter stacker) that so delighted the brothers; specifically, they were keen to experience the 16-station gathering machine with Asir 3 automatic signature image recognition and a criss-cross system. “In terms of quality assurance, the Asir 3 is an important selling point for us,” says Jimmy Ahlrik. “Showing what we can do” Another dimension is that very few of the signatures delivered by the printing houses have a bar code. “We already regularly draw our customers’ attention to the benefits of using a bar code”, stresses Johan Ahlrik. “But in the future it will become even more important to create a culture of mutual dialog with our customers and really show them what our perfect binder can do.” Currently, JKJ is only using a hotmelt process. As the Pantera is also equipped for PUR processing, however, the company regularly reminds customers of the drawbacks of hotmelt processing. 

www.jkj.se 33

Softcover Production

When Frequent Changeovers Are Needed, the Acoro Is the Right Solution As the circulations of its softcover products can vary considerably, the perfect binder at Printera Grupa in Sveta Nedelja, Croatia must undergo frequent job changeovers. This is why Printera, which ranks among the leading printing houses in Croatia, has invested in the Acoro line from Muller Martini, well-known for its fast Make Ready system.

1 E Printera prints and binds a wide range of softcover products, including books, school books, monographs, catalogs, magazines and company brochures, for around 5000 customers, predominantly from Croatia. This means they must print and bind product thicknesses ranging from 3 to 60 millimeters (around 1000 pages). In addition,they must use different sizes (from A6 to A3) while also printing in circulations 34

that vary from 300 to 20,000 copies. “That's why we have to change over our line frequently according to the job,” says Tomislav Krajacic, Chairman of the Executive Committee. Long-Standing Partnership As a result of the frequent changeovers it carries out, the company needs a userfriendly perfect binder with a Make Ready

system. When Printera was considering installing a replacement for its 20-year-old perfect binder from another manufacturer, they opted relatively quickly for the Acoro from Muller Martini – notable as the first perfect binder of this type in Croatia. For many years, Muller Martini Zagreb has worked with Printera and its predecessor companies (see box) in a partnership that has stood the test of time. “We are not onMuller Martini Panorama Spring 2011

Young Company with a Long Tradition ly impressed by their machines, but also by their service and their quick delivery of spare parts,” says Production Manager Mirko Mamic. “This meant that choosing the Acoro was an easy decision.” Superb Binding Quality The new perfect binding line with 16-station gathering machine, criss-cross device, Merit S three-knife trimmer, CB 16 counter stacker and Book Data Center (BDC) was put into operation last summer. According to Tomislav Krajacic, it fulfilled all the company's expectations: “Our machine operators got to grips with the Acoro very quickly, and our customers have been commending us on the superb binding quality.” The majority of the products are glued using PUR, but Printera is also still employing a hotmelt process. The gathering machine is also used to produce book blocks that are thread-sewn.

1 The Book Data Center (BDC) enables Printera to record all the relevant book measuring data for the entire Acoro perfect binding line.

Printera Grupa, who also rely on two Presto systems and an Apollo stacker from Muller Martini in their saddle stitching processes (for magazines with circulations of up to 100,000 copies), has earned a good reputation in the Croatian graphics industry thanks to its highly creative products. An example of this approach is the company's own brochure, which is presented in the style of a menu. “We show our customers how they can create added value through printed products, such as by adding a cover flap to adhesive bound products,” says Tomislav Krajacic. “Our recipe for success is to support the customer throughout the entire process, from initial consultation right  through to delivery.”

www.printera.hr

2 From left: Draženko Mamic (Production Manager), Željko Pokupec (Director of Muller Martini Zagreb), Tomislav Krajacic (Chairman of the Executive Committee) and Ivana Šah (Printera Communications Officer) in front of the new Acoro perfect binder at Printera. 3 The Acoro at Printera is the first perfect binder of this type in Croatia.

Muller Martini Panorama Spring 2011

Although Printera Grupa has only existed since January 2009, the company can look back on a long tradition. Printera was created from a merger between Kratis (founded in 1990 in Sveta Nedelja [see “Panorama” 1/07]), Gipa (founded in 1989 in Zagreb) and Bauer Grupa (founded in 1999 in Samobor). “As we have brought together a great deal of experience, we can claim without exaggeration that we have become three times better in terms of quality, price and speed,” says Ivana Šah, Communications Officer at Printera. Representatives from all three predecessor companies sit on the five-person executive committee: E Tomislav Krajacic (Chairman/ex Kratis), E Robert J. Krajacic (Sales Manager/ex Kratis), E Draženko Mamic (Production Manager/ex Gipa), E Mirko Mamic (Production Manager/ex Gipa) E Krešimir Bauer (Finance Manager/ ex Bauer) Printera employs 130 people in a two and three-shift system.

Press Delivery Systems

Wanted: A Full Service Provider for Complex Press Delivery Systems Producing over 900 newspapers, peaking at over five million copies in certain weeks, the publishing company and printing group LINUS WITTICH is Germany's market leader for official journals and bulletins, as well as a wide range of other publications. Muller Martini press delivery systems with cutting systems and stackers are on hand at the two printing sites, Herbstein and Herzberg, to ensure that finishing these publications takes no time at all.

E The LINUS WITTICH publishing company has a long heritage: it was founded almost 50 years ago and today is Germany's market leader for official journals and bulletins. The basis for this success is the 900 local publications, or “citizens newspapers”, that it produces, most of which are free. Nevertheless, Günter Knopp, operations manager of all WITTICH printing sites says: “We are not your average newspaper producer; we're more of a hybrid. We actually print weekly publications in a commer-

cial format; these publications necessitate several hundred plate changes.” In order to fully understand this moderating statement by Günter Knopp, it helps to cast an eye over the run structure of the WITTICH newspapers printed at the three sites (Föhren, Herbstein and Herzberg). Depending on the site in question, the publisher's average print run is between 2100 and 9000 copies, fluctuating in the region of a low of 200 and a high of 50,000 copies per title. In terms of print runs, one single

periodic title printed by the LINUS WITTICH Group comes in somewhere over the 100,000 mark. In contrast to the page counts, which can range between 8 to 80 pages, the size is identical in 99% of the newspapers (most of which are pressglued, with very few being stitched): A4 or A3 with a fold. Therefore, the major challenge for LINUS WITTICH is ensuring that the wide range of short runs are quickly fed through the six CROMOMAN press delivery systems via conveyors, cutting systems

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Muller Martini Panorama Spring 2011

Press Delivery Systems

6 Two Preciso rotary trimmers are soon destined for the WITTICH plant in Herbstein. The Preciso is known for its clean three-page trimming. 7 LINUS WITTICH is putting its trust in two Listo stackers at its Herbstein plant.

6 Listo really plays to its strengths here,” says Günter Knopp. “You can really tell that it's not just a commercial work stacker or newspaper stacker.” E Thirdly, the Muller Martini Mailroom Production Control (MPC) system, which is designed to guarantee automated stack formation, was easily integrated into the workflow process thanks to an existing interface to the LINUS WITTICH software product – and all with a minimum amount of effort. Thanks to this system, products are safely and reliably processed into varying stack sizes. “These software components are also a key factor in why we decided to work with the reputable provider 40

7 Muller Martini,” continues Günter Knopp. “The system in Herbstein proved to be such a success that we decided to employ the same solution in Herzberg, and this is something that we have never regretted.” New Products Constantly Being Printed Other newspapers will soon be rolling over the production line via printing presses and finishing systems in addition to LINUS WITTICH newspapers. “There are constantly new print products to accompany our newspapers,” says Günter Knopp – products such as magazines printed on newsprint with high-quality covers, tourist information inserts, travel journals, infor-

mation brochures about communities, and much much more. “These products enable us to demonstrate our knowledge and our proximity to local communities,” explains Knopp. These products ensure, firstly, that LINUS WITTICH is able to utilize existing machine capacity to take on extra printing work, and secondly, is using its vast expertise from the newspaper industry. “It is also thanks to the strong emphasis we place on local publications that the order situation looks so rosy in these difficult times,” says  Günter Knopp.

www.wittich.de Muller Martini Panorama Spring 2011

Services

“The Remote Solution Makes a Significant Contribution to Optimizing the Corona” Southern Print Ltd., based in Poole (England), is putting its faith in the MMServices module MM Remote Online for the Corona C18 perfect binder it put into operation last summer. This is an absolute necessity, as Managing Director Paul Toms reveals in an interview with “Panorama”.

From left: Paul Toms (Managing Director at Southern Print), Richard Dance (Muller Martini England Sales Manager) and Reto Hofer (Muller Martini England Technical Manager) in front of the Corona C18 at Southern Print.

E «Panorama»: What made you choose the MMRemote Online service solution from Muller Martini? Paul Toms, Managing Director, Southern Print Ltd., Poole (England): We operate on a 24/7 basis, meaning our machines need to be running around the clock. As we produce many magazines under strict time constraints, reliability is a crucial factor. Our customers not only want highMuller Martini Panorama Spring 2011

quality products, but they also insist that we deliver these products by the deadlines agreed in the contract. That's why it was clear to me that we needed a remote solution for our new perfect binder. It makes a significant contribution to optimizing the Corona.

“Our customers not only want high-quality products, but they also insist that we deliver these products by the deadlines agreed in the contract.”

In view of major pricing pressure, increasingly tight deadlines and the high 41

service it offers. For a company like ours that operates 24/7, it is important that a technician is available at all times as we simply cannot afford any interruptions to our production process. If I could improve anything about MMRemote Online, it would be to include a clearer display with an integrated diagnostic system – with icons, for example. That would make resolving problems an even faster process. What does the future hold for optimized service solutions? Will customer's machines be fully networked with the

achine manufacturer so that the mam chine manufacturer can take action proactively? The keyword here is integration. When it comes to our production systems, we do not possess the same high level of expertise as the machine manufacturers. In future, this means graphics companies must look to further integrate their suppliers into their service package, training programs and the maintenance of their machines. 

“We operate on a 24/7 basis, meaning our machines need to be running around the clock.”

The Corona C18 at Southern Print: Rapid Installation, Rapid Production Southern Print Ltd. specializes in magazines and periodicals as well as commercial work, producing over 200 titles that are published regularly, primarily for the British market. Their smallest runs consist of just 500 copies, while the largest runs comprise over a million. The range of products produced by the company is equally broad: Complex consumer publications with many pages, inserts and glued-in cards are produced alongside simple products consisting of just one or two signatures. This means the perfect binding process needs to be sufficiently flexible – and the focus here is on changeovers. For this reason, Southern Print has been putting its faith in Muller Martini systems for a number of years. Last summer, Southern Print needed to replace a Normbinder that was severely damaged in a fire at its production facility in Poole, so the company invested in a Corona C18 line featuring a new high-performance 3697 gathering machine, an Orbit three-knife trimmer, a CB 18 counter stacker and Cohiba automatic palletizer. “Aside from the technical aspects, we were also persuaded to continue working with Muller Martini by the many years of positive experience we have had with their service,” says Paul Toms. The managing director goes on to

Muller Martini Panorama Spring 2011

mention another factor that swung their decision to install the Corona: “When conducting our machine evaluation, we also considered our customers and their specific requirements – many of them have an excellent understanding of perfect binding.” Paul Toms was already impressed by the rapid commissioning process (“In my 25 years in the graphics industry, I have never known there to be such a short period of time between ordering and installing a new machine”), and his impressions of the first few months of operation have also been consistently positive. “Thanks to the control systems, such as Asir 3, Asac and Quako, the products are completed to an outstanding level of quality. The Corona is also very simple to operate, which is why we are mainly producing products in the top quarter of the speed range.”

2 1 Southern Print produces over 200 magazine titles. 2 The high-performance ZTM 3697 ensures the signatures are gathered quickly and reliably.

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