Finishing 4.0 applies as much to conventional production as it does to digital

In line with the themes ‘Industry 4.0’, which stands for the digitization and connectivity of processes and systems, and ‘Finishing 4.0’, which stands for numerous innovative, intelligently combined industrial solutions for print finishing in both the digital and offset segments, Muller Martini presented solutions that optimize touchless workflows in the production of magazines, brochures, books, and newspapers.

Like Industry 4.0, Finishing 4.0 is about producing customized and variable print products cost-effectively and efficiently using means of industrial production. It was highlighted that amid the excitement about customized and personalized (hybrid) print products in ultra-short runs, it is often forgotten that the offset segment still accounts for some 90 percent of the global printing volume. In fact, the exact same (touchless) workflow requirements apply to conventional printing and print finishing as in the digital segment: make-ready times should be short, production should not require manual intervention by the machine operator if possible, and transitions from one job to the next should be touchless.

“There is major potential for development in customized, variable and high-quality printed matter. However, it needs to be produced efficiently. The numerous advantages of Finishing 4.0 solutions are by no means limited to digital or hybrid systems. Fully automatic systems that reduce interventions by machine operators to an absolute minimum both during and between production runs are also called for in conventional print finishing,” says Bruno Muller, CEO, Muller Martini.

Primera MC saddle stitcher

The new Primera MC saddle stitcher enables short processing times with Motion Control Technology. The feeder and gathering chain are automatically synchronized, and servo drive technology for all stations (feeder, stitching machine, gathering chain, three-knife trimmer) reduces the setup times. The modular saddle stitcher can be easily converted to the Primera MC Digital for the efficient processing of digitally printed products.

Thread sewing automation

The Ventura MC Digital has been added to the thread sewing machine range (consisting of the Ventura MC 160 and Ventura MC 200). It is coupled with a flat pile feeder, pocket folder/processing folder for products from digital sheet-fed or web printing presses (with a sheeter) up to a signature size of B2 and a speed of 9,600 cycles per hour.

Three-knife trimmer

The InfiniTrim three-knife trimmer, with its unit drive technology for all grippers and knives, enables full size and thickness variability from book to book and ensures the correct positioning and pressing of every single product fully automatically. The InfiniTrim comes into its own as the perfect inline companion to Muller Martini’s new three-clamp Vareo perfect binder.

For the production of individual softcover and liner brochures, the material to be trimmed is first fed horizontally, and the dimensions for the head trim and the finished trimmed size are registered via barcode. The subsequent infeed wheel positions the book vertically. It is then conveyed by a servo-driven gripper from that position to the first trim zone for the head trim. The desired stopping point corresponds exactly to the position of the trimming line. Straight after the head trim, the book is conveyed using servo-driven transfer units to the specified position for the front trim and then to the foot trim zone. Following the foot trim, the book is transferred to the delivery belt, without the machine operator having to intervene during the entire process.

New connectivity options for digital workflow

The Connex data and process management system offers new standard interfaces to three partners – Prinect by Heidelberg, HP Production Center and Switch by Enfocus – in addition to standard integration via JDF and JMF, in order to meet the requirement for connectivity of individual process steps.

Features of Connex include (1) Connex.Info, which makes production transparent by providing a constant overview of the production lines and status of the various jobs; (2) Connex LineControl for the SigmaLine, which integrates digital printing with print finishing at the highest level; and (3) Connex LineControl for saddle stitching/perfect binding/hardcover (production planning and control), which distributes job data to the connected Muller Martini production lines for the automated pre-adjustment of these production lines.

“Shorter runs and the capabilities of printing presses today make a seamless workflow essential for many applications. That is because it is only possible to make products in one operation and therefore cost-effectively if the entire process is completely automated and integrated. With the Connex data and process management system, it is possible to optimally automate all Muller Martini systems, from a standalone machine to complex production lines. With new standard interfaces, Connex can facilitate communication between Muller Martini machines and the workflows of other manufacturers,” explains Bruno.

SigmaLine featuring three new functions

The SigmaLine digital book production system has three new functions. The top speed of the SigmaFolder II is now 1,000 feet. The newly developed on-the-fly format change function ensures that format changes are performed as a seamless, touchless workflow, without the printing press having to be halted or the machine operator having to intervene. Three new modules of the Connex process and data management system enable VDP production. Personalized book blocks, each with a completely different page count, size, book thickness and content, can be produced in sequence in runs of one copy using the SigmaLine digital book production system.

The book titles can then be perfect bound in sequence using the Vareo perfect binder, which has a servo motor for each of its three clamps and are individually driven. Finally, the three-sided trimming of books that vary from product to product can be performed using the InfiniTrim.

Customer portal and support glasses for troubleshooting

MPower, a customer portal which can be used via a PC, tablet or smartphone, enables troubleshooting and provides customers with integrated solutions as part of Muller Martini’s after-sales service.

Live View, for instance, gives a current overview of the machines and provides real-time information about their performance and production status (production, malfunction, stop). In addition to a status report of the current e-call, there is also an overview of the latest inspection and maintenance reports.
MPower is an integral part of Muller Martini support agreements, which come with every purchase of a new Muller Martini machine during the warranty period.
Support Glasses are WiFi data glasses featuring a microphone and headphones for interactive troubleshooting. By visualizing the malfunction using live streaming technology, customers receive suggestions through the data glasses on how to fix the problem efficiently. A video camera integrated into the Support Glasses enables production processes to be analyzed in detail and targeted advice to be given accordingly.