Post Press News - Rima

POST PRESS NEWS
Worldwide News about Post Press – August 2013
RIMA-SYSTEM and Müller Martini
Post Press in a new dimension for the biggest
heatset press in the world.
This year the largest heatset press of the world – consisting of two 80p
Lithoman IV presses which can run in duplex mode – is going into
production at Kraft-Schlötels, Germany.
The press will be equipped with a highly automated Post Press System
realized by RIMA-SYSTEM and Müller Martini, cooperation partners
since summer 2011.
08
Editorial
One year later our DRUPA-slogan looks more up-to-date than ever:
Let’s accept the
challenge!
At DRUPA our message was clear – we need
to accept the difficult situation and have
to find the right answers. At that time our
industry was undergoing a dramatic structural change, the outlook was grim and the
investment in new web presses had dropped
over 50% compared to the 2008 values. One
year later we realize that the situation has
not improved at all, no “U”, a “W”-recovery
will bring us back the volumes and margins
seen in the past. Some applications / markets will drop even further while others will
see some positive trends. The light at the
end of the tunnel is rather dim.
The last years we have been working very
hard to find the right answers for this
rapidly changing reality. Answers which
eventually resulted in new technologies, new
services, new features, special solutions,
etc. – all supported by a strong & reliable
team. The goal was clear – how can we help
our customers to improve their productivity
and efficiency?
Did we meet the requirements and expectations of our customers? Let’s look at what
happened since DRUPA:
• More than 70% (in terms of investment it’s even more) of the new presses sold at
DRUPA are equipped with RIMA-SYSTEM
Post Press,
• This trend continued for the rest of the
DRUPA year and into 2013 with orders like
Bruckmann (Germany), Schaffrath (Germany), Leykam (Austria), Quad, Brown, Fisher
Printing, Thomson (USA), Roto Armor &
La Galliote Prenant (France),….
• At the same time we have been able to
push R&D and to present and install several new technologies in areas like personalized retail, mailing stackers, book block
stacking behind digital presses, etc.
• Another important area we have been
professionally serving for a few years are
re-engineering and optimization projects.
The volume of these projects has risen
dramatically over the last years and a
special knowledge and project handling is
required.
What do these facts tell us? It’s not about
selling a new stacker, trimmer or robot,
it’s about understanding needs and giving
solutions! And these solutions can have
completely different technical and financial
requirements – from a new and highly automated system to a mix of new, existing and
overhauled machines or solutions with new
technologies for special applications. And
it’s also about being straight and honest,
about telling what makes sense (technically
& financially) and what doesn’t – although
in difficult times the “truth is not the highest
traded good”. We are committed to finding
and giving the right solutions. Customers
value our technologies, our product quality
and reliability and the way we handle our
projects – from the pre-sale consulting to
the start-up phase. As a result we are today
the most complete Solution Provider in Post
Press.
Because of the growing importance of reengineering and optimization projects this
issue of the Post Press News will focus on
this topic. The Bruckmann article will outline
why this group invested 3+ million EUR to
completely renew and optimize the Post
Press of their three rotogravure presses, the
Burda article shows a very similar approach
but with a different outcome. Several other
examples from around the world show the
whole spectrum of optimization – from a
single machine to complete systems.
At the same time in the market of complete
automation behind high speed / high volume
presses RIMA-SYSTEM remains the main
player. Two quick examples: the most productive web press in the world (Lithoman
160p @ 50.000 cph) at Kraft-Schlötels and
the most productive web press in Austria
(Lithoman 48p @ 70.000 cph, short grain)
will both be equipped with RIMA-SYSTEM
Post Press.
We are fit for the future. Talk to us if you feel
we can help you optimize your Post Press
operation!
Enjoy reading,
Klaus Kalthoff
Content
Content
RIMA-SYSTEM Technology for
Bruckmann Tiefdruck
Page 4
High-Speed log stacking at Burda
Nürnberg in Germany
Page 9
Improved Post Press
Page 10
More Orders and Installations
Page 15
Leykam invests in RIMA-SYSTEM
Page 16
China goes automation
Page 18
Kraft-Schlötels – biggest heatset
press worldwide
Page 19
Editorial
Fit for the future!
Complete Post Press
reengineering at
Bruckmann.
TSB Bruckmann
RIMA-SYSTEM technology for Bruckmann Tiefdruck
Increased quality and
greatly reduced manning
levels
Running a gravure printer viably is undoubtedly one of today’s biggest challenges in the printing industry. When Oliver Schwab was
made managing director of Bruckmann Tiefdruck GmbH & Co. KG in Oberschleißheim in 2008 he was under absolutely no illusions
about this, having spent his entire professional career in gravure printing. Now, five years on, Schwab and his team have achieved
much and ensured that this member of the Bagel Group will be a major player in European gravure printing following a multi million
euro investment in completely new postpress systems for three of its four production lines. Schwab believes that this represents,
“An extremely positive sign of support for our strategy by the shareholders… and recognition of the fact that we have put our house
in order in Oberschleißheim.”
Bruckmann Tiefdruck has been operating in
Oberschleißheim on the north-west outskirts
of Munich since 1968 and became part of
the Bagel Group in 1999. At the time of that
takeover an additional 2.70 m wide press
was installed and since then Bruckmann has
operated four gravure lines: two KBA TR4S
presses with a usable width of 1.60 m and
two KBA TR6B presses with a usable width
of 2.65 or 2.70 m. These widths explain why
Oliver Schwab believes that, “We are more
an offset printer with gravure technology.”
Schwab is perfectly positioned to make
comparisons. In 2011, sales, order processing and production planning were bundled
together with those of TSB and Burda-Druck
into a joint company, B&B Media Services.
Allocation of jobs secured by B&B to the
TSB and Burda gravure plants, with their
different sets of equipment, has helped to
significantly improve the job structure at
Oberschleißheim. That being said, even prior
to 2011 it was fairly unusual for Bruckmann
to print catalogue and magazine signatures
due to the configuration of the folders; three
of the four being equipped with formers.
The Bagel or TSB Group also owns a web
offset printer, Bagel Rotooffset, located in
Meineweh near Leipzig. This is equipped
with 80 and 96-page web offset presses,
which have usable widths that are very
similar to those of the Bruckmann presses.
Direct cost benchmarks can therefore be established, especially when there are orders
that could be produced either by means of
offset or gravure. This is no longer so very
unusual. Oliver Schwab comments, “There
are customers who no longer explicitly
request offset or gravure. What matters to
them is delivering high quality to deadline
– and, of course, at the right price.”
In Oberschleißheim, as in Meineweh, the finishing lines primarily deliver brochures, i.e.
finished products that may have been glued
or stitched inline with two or three folds.
This means that the Post Press technology
has all the more impact on productivity,
quality and costs.
Staffing costs reduced
So what exactly did Schwab and his team
have to deal with in order to put their house
in order?
Staff costs are – besides paper, ink and energy – the biggest cost factor in printing and
they are easier for the management and staff
themselves to influence than paper costs.
They are a decisive factor in the success or
failure of a company, and the Post Press
lines are amongst the most labour intensive
areas of production.
Oliver Schwab, Managing Director at Bruckmann
Tiefdruck GmbH & Co. KG, is confident that the
company is fit for the future with its new
RIMA-SYSTEM Post Press lines.
TSB Bruckmann
Until a few months ago Bruckmann followed
the traditional building block principle in
Post Press: those units required for the cutting, transporting and stacking of a particular job would be assembled with corresponding amount of labour to create the relevant
finishing line. Investment decisions were
also driven by the tasks or units required at
the time. Transportable finishing lines have
advantages but also unquestionable disadvantages. “It doesn’t do the units any good
if they are moved to a different place every
third day”, is how Oliver Schwab sums up
his experience.
At the request of the Bagel shareholder,
the managing director had put his plans
for the Bruckmann plant down on paper as
long ago as 2008 and even then automated
deliveries formed a key component of the
concept. However, its implementation was
put on hold whilst Europe’s gravure companies sought various ways to consolidate and
position their plants. Nevertheless Schwab
worked to optimize production processes
and to reduce staff costs and he did so successfully. By 2012 the workforce had been
cut from around 200 to some 160 permanent employees, without any reduction in
capacity.
Into the new Post Press age
A decisive step was taken last year when the
Bagel shareholders gave the green light for
the purchase of the new Post Press equipment. Their supplier, RIMA-SYSTEM, was
ready to go straight away, having already
manufactured a number of key modules. As
a result, Bruckmann was able to leap into a
new prepress age within the space of half a
year (including three and a half months of
installation time).
The Düsseldorf machinery manufacturer
had to overcome competition from various well-known names but the most
compelling argument in its favour came
from the Tiefdruck Schwann-Bagel plant in
Mönchengladbach, where RIMA-SYSTEM
had already trialled several of its new developments. Oliver Schwab was therefore able
to draw on his experience of working for
several years in a RIMA-SYSTEM equipped
plant.
Hans-Josef Pflipsen is the German sales
manager for RIMA-SYSTEM and he recalls
that, “at the end of June 2012 the final decision was made in favour of RIMA-SYSTEM
and we started to build the lines at the end
of August, with a constant objective of keeping down time to an absolute minimum.”
They pulled it off, and each individual press
only had to be taken out of production for
three or four days at most. Oliver Schwab,
“Within a really short space of time three
lines were all of a sudden complete. It was
also great fun.
The people from RIMA-SYSTEM were both
highly effective and committed.”
In the case of the 1.60 m wide presses 3
and 4, the Post Press lines were gradually
integrated whereas with press 5 it was all
done in one go. On 17th December 2012
the final robots started operating and
today three of the four Bruckmann gravure
presses are equipped with the automated
deliveries that Oliver Schwab envisaged in
principle back in 2008.
TSB Bruckmann
Each Post Press configuration consists of
various low and high level conveyor systems, two RS 840 double stream trimmers,
two RS 34 S Lift compensating stackers
with RS 110 blocking units and an RS 400
palletizing robot. Each of the three palletizers is fitted with automatic pallet transport
systems, interleaf sheet feeders and Paletti
operating software.
One important goal was to bring all the
deliveries together in one easy to oversee
production section. This means that instead
of the three or four staff required when the
bundles were still stacked by hand, only one
worker per shift is now permanently assigned to each line and he or she also handles
the presetting. With three presses running
for three shifts, this has helped Bruckmann
Tiefdruck reduce manning levels by over 20
operators. It has also made it possible to
completely eliminate subcontractors, who
in past years consistently numbered around
25.
However, the new manning levels meant that
all units needed to be reachable quickly. To
make this possible RIMA-SYSTEM drew on
its broad product range to create lines with
heavy duty high level and horizontal conveyors that allowed the compensating stackers
and palletizing cells for presses 3 and 4 to
be placed side by side although the folder
delivery for press 4 is in the basement. Even
the delivery for press 5 is only a few steps
away despite what Schwab describes as,
“challenging space constraints”. Raising the
conveyor belts above head height has
allowed the Post Press lines to cross each
other and permits direct access to all units.
Even though it now concentrates on finished
products, Bruckmann still has to cope with
a wide range of signatures stretching from 4
up to 128 pages. The pages themselves are
largely A4 and the grammages lie between
34 and 115 g/m2. Nevertheless, since the
modules are set up automatically and a
couple of touches on the touchpad are all
that is required to select the production path
and the pallet arrangement for the stacking,
it is now possible to switch production
faster than ever.
“Much more relaxed”
After the first three months, Oliver Schwab
offers this preliminary assessment, “Things
are much more relaxed in Post Press now.
Things are quieter and even the pallets look
a bit better than when stacked by hand.” He
also praises the trim quality, even though
it has not yet been necessary to change a
single knife on the rotary trimmers.
There was a little concern in advance about
the spiral modules, which had been adopted
as a space saving solution for changing the
height and direction of the product stream.
“However, so far there has not been any
kind of problem at all.”
RIMA-SYSTEM has been using spirals
successfully for years when the direction of
the shingled stream needs to be changed
at high speed. In contrast to conventional
curves – where the products always tend
to drift at the end of the curve and therefore enter the next conveyor section at an
angle – in spirals the tail edges of products
are fixed right up until the last moment.
This ensures cleaner transfers even at high
speed. At Bruckmann it has been possible
to achieve a throughput in excess of 90,000
copies per hour in two-up production, which
in turn means that the robots stack around
500 bundles per hour.
What about the overall Post Press wastage
rate? Schwab, “Initially it was somewhat
higher but this was probably due to operator
errors. Currently it is below the previous
levels.” According to Schwab, staff who,
“were used to using a spanner on the
system”, tend to, “adjust the settings”,
unnecessarily.
The printers can do a lot for quality. The
old rotary trimming systems often suffered
disruptions because a poor product stream
triggered the light barriers and stopped the
trimmer. All hell would break loose in the
hall and printers and assistants would have
to manually remove the shingled stream.
Schwab, “My printers have quickly learned
that the better the product that emerges
from the folder, the more cleanly it is aligned, the fewer the problems they encounter
with the delivery.”
Confidence
Bruckmann Tiefdruck is now fit for the
immediate future with its new
RIMA-SYSTEM Post Press lines. “Now we
just need the orders”, comments a smiling
Oliver Schwab. 2013 began better than the
previous year and so a feeling of confidence
pervades the Oberschleißheim plant despite
the various bits of bad news from the
printing industry.
Click here to see
Post Press live at
TSB Bruckmann.
Log Stacking | Burda, Nürnberg
High-Speed log stacking at Burda Nürnberg in Germany
High-Speed log stacking
at Burda Nürnberg in
Germany
Last year, the rotogravure printer Burda opted for new high-speed log stackers from RIMA-SYSTEM to increase the
output and stability of their production behind a KBA TR7B press.
Last year, the rotogravure printer Burda
opted for new high-speed log stackers from
RIMA-SYSTEM to increase the output and
stability of their production behind a KBA
TR7B press. This was necessary as the
group made a strategic reorientation where
each plant should focus on the efficient
production of a certain kind of production.
While the sister plant in Offenburg was focusing on finished products (mainly trimmed and untrimmed retail) the Nürnberg
plant was optimizing their abilities to print
finished products.
Mr. Christoph Barth (Technical Director of
the Burda Group) and Mr. Osbild (Managing
Director at Burda Nürnberg) shook hands
with the team of RIMA-SYSTEM.
The Burda group had already good experience with the older version of the log
stacker, the RS 600, at their plant in Nürnberg. After test installations of the new machine in Nürnberg and in Offenburg to check
the performance with a wide range of different grammages, coatings and paginations
the customer was convinced that the RS
610 was the best machine for their needs:
The connection to the existing conveying
system has been realized with high-speed
spiral, “c”- and “s”-conveyors which transport the shingled stream safely to the log
stackers by keeping the products between
belts and avoid a misaligning of the copies
as it can happen with standard flow-turns.
The two RS 610 HS heavy duty machines
have replaced two existing CIVIEMME vertical log stackers which have been running
successfully for many years. Together with
the RS 610 HS log stackers two new PL 86
log palletizers with slip sheet feeders and
an automatic pallet conveying system with
pallet magazine have been installed.
After 6 months in production (start-up was
mid of December) the customer is more
than happy with the new horizontal machines. Convincingly easy set-up and operation and the great log quality combined with
a high grade of automation and accessibility
are major benefits of the RS 610 HS.
Click here to see
Post Press live at
Burda Nürnberg.
Tech Info: RS 610 HS
High speed horizontal log stacker
Variable configurations
Special gapping system
Fully servo-driven
Automatic or semi-automatic adjustment
One-side operation and maintenance
Options: Remote Maintenance, PPMS,
JobTicket, ZMR-Control
specs
cycle time:
pagination:
sizes:
log length:
>27s
4-144p
delta-tabloid
600-1200 mm
Improved Post Press
Increase productivity
& save costs – with
improved Post Press
Reduce waste, minimize manual labor,
improve workflow, stop moving equipment,
focus on main (“cash cow”) productions,
standardize machines and processes,
specialize on selected products and formats
– there are several areas of improvement. At
the end it’s about having an operation which
is optimized for the work you are producing.
This is not always the case. There are still
many examples where printers do not have
the right machines, the best configuration
and an in-line workflow for the products
they have to run. In markets which are
highly price-sensitive competing with the
“wrong” equipment becomes very expensive.
The “Bruckmann-story” in this Post Press
news is an in depth project portrait from a
group who evaluated the market requirements, their ability to serve it with their
actual equipment and the costs related to it.
Eventually they took the decision to focus
on retail production and to optimize the
deliveries of three presses to best serve this
market. Read more about their experience.
The “Burda Project Portrait” has a similar
story. Here also the decision was taken
not to do all kind of work on every press.
The result was to reorganize the delivery
of two rotogravure presses and to focus
on log production. A centralized and highly
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Used and factory overhauled
machinery for sale.
Note: Conveyors (Straight Conveyors, Diverts, FlowTurns, etc) are available on request.
10
automated log stacking and log palletizing
system was installed. The results are higher
press speed, less waste and reduced labor
costs. Read more about the specifics of this
installation.
In addition the following overview shows
very different optimization projects from all
around the world. They range from basic automation (replace manual pile down with an
entry level stacker) to a simple replacement
investment (e.g. a log stacker to replace a
compensating stacker) to the add-on of new
features (like e.g. trimming or robotic palletizing) up to the redesign of a complete post
press system. All these examples also teach
us that based on requirements, budget and
technical specification the best compromise
has to be found. This includes the configuration, the degree of automation and the
type of equipment. It could be all new, 2nd
hand, factory refurbished or a mix of it.
In a first step our new website
http://stockmachines.rima-system.com
with all available demo and 2nd hand
machines might be worth a look. This easy
searchable (by type of machine, manufacturer,…) on-line list gives you a quick
and comprehensive overview. If you find a
machine interesting a PDF-summary with
pictures gives a more detailed description.
And if you need more help, contact us to
discuss the specific needs of your project!
Improved Post Press
Coptip, Italy
Press: Application:
Project: Requirements:
Solution:
Lithoman 72p, heatset
Retail
Replace two existing non RIMA-SYSTEM press stackers with
new RS 36S
Reduce waste, maintenance costs, down-time, improve bundle
quality and average run speed
Installation of two RS 36S double-lift stackers
Grafiche Boccia, Italy
Press: Application:
Project: Komori 32p, heatset
Retail
Add trimming and stacking line
Requirements:
Produce off the press retail products,
run untrimmed productions into a compensating stacker
Solution:
RS 830 trimming line with RS 34S compensating stacker
11
Improved Post Press
Grabados Nacionales, Venezuela
Press: Application:
Project: Requirements:
Solution:
Baker Perkins 32p, heatset / Lithoman III 32p, heatset
Magazine, catalog, directory
Replace non RIMA-SYSTEM stackers behind Baker Perkins
add log stacker to Lithoman
Reduce manual labor, introduce basic automation, comply with
labor rules, deliver logs to bindery for the Lithoman productions
Installation of two RS 34S stackers for the Baker Perkins
Installation of one semi-automatic vertical ST 2000 log stacker
for the Lithoman
ACES, Argentina
Press: Application:
Project: Requirements:
Solution:
12
Harris book press, coldset
Book printing
Replace manual pile down and log building with semi-automatic
log stacker
Reduce manual labor, improve bundle quality, get counted logs
Installation of a semi-automatic vertical ST 2000 log stacker
Improved Post Press
Pindar, England
Press:
Application:
Project: Requirements:
Solution:
Sunday 4000, Heatset
Retail, Magazine
Complete Post Press for High-Speed Printing machine
Minimal start-up times, good accessibility, high flexibility
System with 2x RS 840, 2x RS 36S, 2x ST 8000, 2x RS 400
WebStar, Australia
Press: Application:
Project: Requirements:
Solution:
Rotoman 24p , heatset
Magazine & catalog
Replace existing log stacker with higher performance log stacker
Reduce down time & maintenance costs, improve log quality,
increase average run speed & up-time
Installation of an automatic horizontal RS 610 log stacker
Obeikan, Saudi Arabia
Press: Application:
Project: Requirements:
Solution:
Muller Martini Saddle Stitcher (3x), Kolbus Perfect Binder (1x)
Catalog & books
Replace manual pile down with basic automation
Reduce manual labor, make counted and compensated stacks of
stitched and perfect bound magazines
Installation of three RS 11 and one RS 33 bindery stackers
13
improved Post Press
RotoCobrhi, Spain
Press: Application:
Project: Requirements:
Solution:
Lithoman IV 80p
Retail
Add in-line trimming
Produce off the press retail products
RS 830 trimming line with RS 36S compensating stacker
Stibo, Denmark
Press: Application:
Lithoman III 32 p short grain, heatset
Retail, magazine & catalog
Project: Install a 2nd hand press with a complete post press configured
of new, existing and factory refurbished machines
Requirements:
Complement the existing machines with a short grain press for
highly automated, efficient output
Solution:
Complete system with floor (existing) & overhead (refurbished)
conveyors, double stream trimming line (new) with stackers &
log stacker (existing) and palletizing robot (refurbished).
14
Orders and Installations
More Orders and
Installations
Thomson Reuters, USA
ST 4000 vertical log stacker for short logs with ZMR (Zero Make Ready)
Thijsen, NL
Factory overhauled RS 3210A high speed stacker
Arcangel Maggio, ARG
RS 34S stacker
CSP Grafica Editoriale, IT
RS 36S replacing a non RIMA-SYSTEM stacker
Parzeller, GER
Factory refurbished ST 220
La Galliote Prenant, FR
Center cut trimmer
El Universal & El Horizonte, MEX
One RS 34S stacker for M600 & two RS 34S stackers for GOSS Community
Quad Xochimilco, MEX
Complete Post Press for new PCF folder for existing S3000 press
Neef & Stumme, GER
Factory refurbished ST 320 for new M600 press
Infopress, HUN
Complete Post Press for 2nd hand 48p press
Fisher Printing, USA
Complete system with four RS 36S stackers for retail production behind S3000 press
RRD Warsaw, USA
Special solution with several RS 20 high speed stackers
Quad Oklahoma, USA
Complete system, double stream trimmers, RS 36S stackers, integration of RS 400 robot
VPM, GER
RS 610 log stackers (2x), RS 820 (overhauled), RS 36S stacker
Cummings, USA
Conveying and ST 220 log stackers (factory refurbished) for new Komori S38D
Moravia Press, CZ
Complete Post Press for new Lithoman press
A-Tribuna, BRA
Conveying and stacking for KBA newspaper press
Pindar, UK
Complete system, two ST 8000 log stacker, two trimming and stacking lines, double robot
UPC, FIN
Two RS 34S compensating stackers to replace two existing machines
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15
Leykam Post Press System
Leykam invests in the
most productive printing
and post press system in
Austria
The LEYKAM Let’s Print group has installed
a 48p short grain web press in its Müllendorf plant. The web press is producing retail
work at a speed of 70.000 cph – single
stream (1 x 48p) or double stream (2 x 24p).
In order to process the high amount of
paper the post press had to match highest
performance standards:
“We and RIMA-SYSTEM are partners for
many years now. This partnership is based
on the convincing performance we have
experienced with the previous installations
which we have behind our other high volume
presses. Therefore it seemed logic to once
more trust in RIMA-SYSTEM technology.
Today, with the whole system running for
6 months we have the proof that we took
the best possible decision – in terms of
the press and in terms of the post press” explains Michael Steinwidder, CEO of LEYKAM
Let’s Print.
The Post Press line behind the 48p Lithoman short grain press includes floor and
overhead conveyors, an RS 840 automatic
double-stream trimming line, two RS 36S
lift stackers with RS 110 blocking units, optional strapping and the RS 400 High Speed
robot. High performance and minimum
manual labor were basic requirements for
the post press system. The ergonomic configuration perfectly matches these requirements. All machines are easy accessible,
the conveyors are either high conveyors or
built into the floor so that the floor space
is kept clear. In addition the machines are
equipped with automatic preset reducing
the set-up time significantly. It is absolutely
impressive to see the whole system produce
24p @ 140.000 cph. And with more than
1000 bundles/h in peak situations the robot
makes sure all bundles safely find their way
onto the pallet.
The LEYKAM Let’s Print group is the biggest
web printer in Austria and one of the biggest
RIMA-SYSTEM customers with more than
10 palletizing robots installed.
16
Leykam Post Press System
Click here to see
Post Press live at
Leykam.
17
Automation for Chinese Printers
RIMA-SYSTEM and Müller Martini connect press delivery and bindery
Efficient Automation for
Chinese Printers
Complete workflow from web printing to finished books − RIMA-SYSTEM
and Müller Martini offer unique opportunities for Chinese printers
The partnership of the two leading suppliers
in press delivery (RIMA-SYSTEM) and in
bindery (Müller Martini) closed the gap
between press delivery and bindery. Customers can now discuss their needs with
one project partner making sure that basic
requirements, future expansions, degree
of automation are completely understood
and configured in order to shape the most
efficient workflow.
Until now in Chinese commercial web
printing mostly 16p presses are used. Most
of the web press production goes to bindery
and is processed into books, magazines and
catalogs. Good bundle quality, intelligent
automation and easy to use machines are
key factors for the press delivery configuration. This allows an optimized processing in
the bindery and a reduced manning behind
the press, both factors directly impacting
the overall efficiency. RIMA-SYSTEM is
perfectly matching these requirements. The
widest Post Press product portfolio in the
market gives the choice of different technologies and adjusted degrees of automation
– from a moveable compensating stacker to
a complete system with full automation.
Since stream feeders are not standard in
most binderies the products delivered from
18
the press should be easy to handle. In a
first step a good compensating stacker can
solve the problem. The RS 34S Lift Stacker
is the perfect solution for compensated (or
uncompensated) loose stacks. The servodriven lift technology allows a perfect control of the stack building process resulting in
a convincing stack quality. The servo-pusher
makes sure the stack is not misaligned during the push-out cycle. The operators can
pile down the stacks without need of realigning them on the delivery table. In addition
the lift stacker is also first choice for retail
application which demand the delivery of
compensated bundles directly off the press.
This makes especially sense when combined
with an in-line three-side trimming line.
For all productions going to the bindery
(books, magazines, catalogs,..) logs have
shown to be advantageous – they keep the
copies flat and compressed, the products in
a log are protected and the storage of logs
is easier and more efficient. Unfortunately
nearly all log stackers only deliver long logs
from 800-1200 mm.
How to combine the advantages of logs
with the requirements of manual feeding?
The semi-automatic vertical ST2000 log
stacker can build very short logs (down to
450 mm) which can easily be handled manually behind the press and in the bindery.
In addition up to a log length of 600 mm
logs in a standard magazine format logs can
also be placed vertically on a pallet allowing
easy feeding of the binders and stitchers.
The ST2000 already automates the shingle
control (waste gate, stream aligner and
squeeze roller), the log separation and the
log building. The operator places the endboards and activates the compressing and
strapping process. Depending on the configuration the log can be picked-up manually
(vertically or horizontally), by means of a
hook or clamp (vertically or horizontally) or
by means of an automatic palletizer (horizontally only). The migration from a manual
palletizing solution to an automatic solution
is possible.
Click here to see
the Post Press
line live!
RIMA-SYSTEM and Müller Martini for Kraft-Schlötels
Post Press in a new
dimension for the biggest
heatset press in the world
It was the biggest order for a web offset
press signed at Drupa 2012. This year the
largest heatset press of the world –
consisting of two 80p manroland Lithoman
IV presses which can run in Duplex mode
– is going into production at
Kraft-Schlötels in Wassenberg, Germany.
The press will be equipped with a highly
modern and innovative Post Press, able to
match the unique press performance. It will
be realized by the Post Press specialists
RIMA-SYSTEM and Müller Martini, cooperation partners since summer 2011.
The total width of the two machines (4.5m)
is more than the largest rotogravure
presses. The huge amount of printed paper
requires a proven Post Press technology
with a performance never seen before.
In addition reliable 24/7 production, high
flexibility and intelligent back-ups are key
requirements for this Post Press configuration.
Behind the manroland folder a newly developed single-gripper system from MüllerMartini will pick-up the two shingled
streams at 100.000cph and deliver the products to the finishing area with the RIMASYSTEM equipment. The products will then
be trimmed, stacked, optionally strapped
and finally palletized with four of the proven
4-axis robots from RIMA-SYSTEM. The
whole configuration is highly accessible so
it can be operated with minimum manning.
Large retail orders, consisting of many
locations (drop points with or without plate
changes) are controlled by the JOB
OPTIMIZER software. The software includes
a real-time “pallet execution engine” that
Click here to see
the former Post Press
line at Kraft-Schlötels
ensures that every pallet is automatically
built according to the specification for this
drop point. It also guarantees that on twoline productions only a single “last” pallet
is generated. This is realized by transferring
stacks from one bundle line to the other at
the end of the run.
The JOB OPTIMIZER software will also be
retrofitted on the two existing 72p presses
at Kraft-Schlötels which are already equipped with Post Press from RIMA-SYSTEM.
For Kraft-Schlötels (together with Westend
Druck in Essen they form the WKS-Druckholding) this project is part of their strategy
to make print and finishing more industrial
and cost-effective. To do so they again
invested in leading technologies – like the
post press solution from their long-standing
technology partner RIMA-SYSTEM.
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