American Printer's mission is to be the most reliable and authoritative source of information on integrating tomorrow's technology with today's management.

Optimizing press delivery

Feb 1, 2006 12:00 AM

         Subscribe in NewsGator Online   Subscribe in Bloglines

One key to production efficiency and cost savings is having advanced press delivery systems and efficient processes in place, to ensure a short and smooth workflow between pressroom, finishing, packaging and shipping operations.

“Automation and flexibility are essential elements in optimizing press delivery,” says Jeff Woloshyn, press delivery product manager for Muller Martini (Hauppauge, NY). “We work closely with each customer, matching fully automated technologies and agile workflow solutions to individual needs. We enable the greatest efficiency and ultimately save the customer money by striving to make certain that printed products can be processed from press to loading dock rapidly, easily and also gently, to assure the best quality.”

Among the globally-dispersed Muller Martini customers who are currently gaining productivity increases utilizing advanced press delivery technologies are Nevada Nimifi, a large print production operation in Brussels, Belgium, along with more than 30 other customers around the globe who have these types of installations.

The largest gains in productivity can be realized by using entirely integrated inline systems. Continuous conditioning ensures good log quality throughout the bundling process. The equation is simple: Better logs = better production. Furthermore, the ability to stack on the spine means refined lap integrity along with better gripping by the feeders, and that translates to a significantly faster operation. The end results include dramatically reduced downtime and much less waste, plus job throughput that is boosted to maximum levels.

Creating top-quality bundles is essential to productive feeding of a saddlestitcher or perfect binder. “Curls on the spine and/or lap must be eliminated, air must be removed from the product, and the product must be compressed flat,” explains Carmine Festa, print finishing product manager for Muller Martini. “It all adds up to easier feeding, better flow, far fewer incomplete products and less misfeeds, which can slow down production substantially and even bring it to a halt.”

Let's take a look at the different components comprising an intelligently engineered press delivery system and how each can optimize productivity.

Automated controls

Muller Martini has developed a proprietary technology called MACOS (Master Control System) that provides single-station control over the entire press delivery operation. With MACOS, operators can monitor and control all areas of workflow or any part of it, either from an intuitive standalone touchscreen or with controls that are built into separate components of the press delivery system. Among the productivity-enhancing features of the MACOS control system are JDF/JMF as well as CIP4 compatibility, and the ability to preset the next job's parameters — enabling operators to instantly call up job specs and keep production flowing with little or no downtime.

Conveying systems

Moving printed materials quickly and safely from press to postpress is imperative in a well-designed press delivery operation. Depending on the specific layout of a facility and the distances products must travel, several conveying systems are available to optimize productivity. Among the most versatile is Muller Martini's Floorveyor, which automatically adjusts to press speed, and includes auto waste tracking and ejection devices to ensure only perfect products are processed through the postpress operation.

Automatic log bundlers

The industry's trend toward shorter runs with more frequent changeovers has increased the importance of high-performance log bundlers that can ensure continuous production flow. As previously mentioned, bundle quality directly impacts the press delivery system's performance. “Muller Martini has raised the performance bar yet another degree with our newest automatic log bundler, the Maximo,” says Jeff Woloshyn. “With Maximo's capabilities to provide perfect bundle formation, facilities of all sizes, whether producing small or large runs, can be confident of virtually uninterrupted production.”

Rotary trimmers

Trimming is an aspect of press delivery in which utilizing the right equipment can save time and money. Today's most advanced trimmers provide precision cutting at full press speed, meaning the speed of an operation itself doesn't miss a beat — resulting in faster job turnarounds and also adding to production cost effectiveness. New innovations are improving accuracy and quality, such as Muller Martini's Compacto rotary trimmer with VibroTec centering infeed. Instead of paddles to align the stream, rollers are utilized, producing a “floating” effect. This results in more consistent alignment and the removal of potentially troublesome static.

Compensating stackers

Incorporating the most advanced stacking technology, such as the Forte compensating stacker, can help optimize press delivery capabilities. The advantages include superior stack quality, accurate count and the ability to handle an extensive range of product sizes.

For more information about Muller Martini's line of press delivery systems and solutions, visit or call (888) 2-Muller.