No longer an afterthought, the finishing department has assumed its rightful position as a vital element in the printing industry constituency. New innovations, and the promise of more to come, have created an unprecedented interest in finishing
While the headlines at this year’s drupa went to the high-speed inkjet machines, developments in the finishing department also raised a few eyebrows. Caryl Holland, Printer Magazines finishing analyst, visited drupa and witnessed the movement toward automation. She says, “When it comes to conventional finishing equipment, one of the main trends to be seen at drupa was the increasing automation even on the ‘economic’ lower cost models. According to Holland, increasing utilisation by being able to handle a greater variety of products was a main finishing theme at drupa.Holland says a good example of combining on-demand digital printing and conventional offset was the demonstration of an automated bindery being given by Horizon at the show. The line consisted of the AFC-566FG combination folder, the StitchLiner 5500 saddle stitcher and the BQ-470 four-clamp adhesive binder with a cycle speed of 1,350 books an hour.
Also linked into the system was the CAB 5000, a JDF-ready integrated 15-clamp binding line with production speeds up to 5,200 books an hour. All the equipment was controlled and monitored by the Horizon i2I workflow system which can also share information with MIS and pre-press systems providing start to finish control of all jobs from order entry to completion.
Rayne Simpson, general manager Print Finishing Australia New Zealand at CPI, found that at drupa, the main focus was unmistakably on reducing labour and improving productivity.
He says, “For example, Wohlenberg Perfect Binding exhibited the Master 7000 binding line with the latest ‘streamer feeders’, including the new Wohlenberg log feeders. The streamer feeders operate differently to the rotary drum system in that it feeds in the same direction as the collator and gives smooth transfer form the hoppers to the collating pins at maximum speed running all stocks. The streamer feeder is designed for ergonomics in mind and is labour friendly with low profile loading and log feeding ability. Each feeder is also removable to allow for tip on or card feeders to be fitted.
“Also on show was their new 90i three knife trimmer. This model is well suited to the New Zealand market, since there are more than 15 installations of 4,000 to 8,000cph models already in operation with printers and bookbinders throughout both countries. The newly designed 90i is the fastest and most automated three-knife trimmer of the Wohlenberg trimmer family. It incorporates an inline counter stacker prior to the trimmer which allows for smooth controlled trimming process has been retained and eliminates the books from marking or being trimmed out of square when pressure is released.”
The Baumann fully automated cutting system integrated with an automatic jogger, also impressed Simpson. He adds, “This new BASA is the first ever design to eliminate the need for an extra person to jog sheets for a guillotine operator, and CPI recently installed the first of the BASA joggers in Australia – prior to drupa!"
Digital influence
Holland says that when digital printing was first introduced, one of its main limiting factors was the lack of finishing equipment capable of handling very short runs, one of digital printing's main advantages. But this is no longer the case, with the emphasis moving to improving quality since, as the quality digital print rises, customers expect higher quality finishes.
With this in mind, Watkiss developed its SquareBack booklet technology, distributed here by Printing Supplies and Machinery. In one pass, it stitches, folds, forms a SquareBack spine, and trims the pages. Holland says, “At drupa, Watkiss unveiled Release 2 of the unit, featuring enhancements including active individual sheet tamping, an optional Hohner stitching head, simplified operation and productivity increases of up to 35 per cent.
“Originally, the company developed PowerSquare as an online unit to operate with high speed cut-sheet printers. However, in response to customer demand, it now offers an off-line unit. Indeed, the debate between on-line or off-line (or near line as some people like to describe it) still rumbles on, although it does seem that on-line operating is becoming more flexible, one of its main drawbacks in the past.”
Ease of Use
Industry experts point out that automation means cost savings and more. Bernard Cheong from Cyber agrees. He believes the new breed of finishing machines are more user friendly, and as manufacturers are keeping their cost down, it is making the machines more affordable.
He says, “Speed is not really important, as most of the runs are getting shorter. Makeready speed and waste are now more important, and are kept to a minimum”. The Shoei folders supplied by Cyber are a case in point, with the company constant focusing on multifunction, miniaturisation, convenience, market-developing effects, and computerisation.
Livio Barbagallo, managing director Muller Martini, sees the increase in automation as part of an organic process. He says, “The newly introduced equipment like for example the Primera saddle stitcher line are mainly building on the well proven technology of our past generation. We focused on simplicity of the handling and even faster set-up which were the main requests from our customers. In addition, we offer high levels of automation already for our mid range machines. The main benefits will be an even easier set-up, which fits in with the tendency of printers also doing the finishing in-house. Plus cost reductions thanks to a faster set-up and a high degree of automation.
Innovation and the future
Barbagallo sees value in innovative thinking, not just for equipment manufacturers but also for the end users. He says, “Trade finishers will have to think outside the square and offer services that the larger groups have a need for but cannot or don’t want to get into. Trade finishers have skill levels that are very valuable for printers, however, only if they are able to transfer those skills into added value for printers.”
John Jenkins and Greg Venter, managing directors of Pacific Lamination and Coatings, are a case in point. They haven't wasted time waiting for others to show them innovations. Jenkins says, “While the market has been tight, we've continued to invest and grow.” The directors believe in using the best equipment and also invest heavily in staff, working closely with suppliers and customers. Venter says, “John and I work closely with our customers, making them aware of what's possible. This approach is very successful.”
Warwick Fletcher, general manager Sharp Print Finishers, agrees that automation and innovative thinking make a difference in the finishing business. He says, “The printing industry seems to be moving that way. In the past I probably haven’t used that technology as much as I could have, but that’s changing. More people are computer literate.”
Livio Barbagallo can see that improvements will have to continue in the future. He says, “Equipment has to be versatile, modular and come with a high degree of automation. Our customers have to be able to offer whatever the market will require in the future, they want to protect their investment from being obsolete by building on existing equipment and having the lowest amount of people operating the equipment.
‘Workflow optimisation in general is a regular topic in every discussion and we can see an increasing awareness of the importance of a properly managed production flow. However, especially in the finishing area there is still room for improvement and although JDF format and the benefits of an ongoing communication flow from and to the equipment are known, a complete implementation is rather seldom. These are the areas we're focusing with our latest generation of equipment. We want to be a partner that can grow with our customers by providing them with solutions that add a value to their bottom line.”
John Jenkins, while admitting the necessity of innovative technology, adds that finishing demands more than that. He concludes, “The future for specialty products relies on service, high quality people, best equipment, well trained people.”
