Due to the excellent log quality of the Vivo, three Turkish companies achieved a 10 % performance improvement in print finishing.

The three family businesses, Tuna, Koza and Ada, all have one thing common: they have all recently invested in a new printing press. Starting production with a Vivo bundle stacker has accelerated their production processes and also reduced their production costs. They have also significantly increased finishing performance thanks to the Vivo’s excellent bundle quality.

Tuna Matbaacilik: Longstanding Collaboration with Muller Martini
Tuna Matbaacilik was founded in 1994 by Tayfun Yildirim who, with his other two companies, Yildirim und Gizem, now employs 115 staff. The company estimates it has increased efficiency on the perfect binder by at least 10%. “Before installing the new delivery system we had to take off everything by hand. But with the printing press delivering 40 000 copies per hour there was clearly need for negotiations in press delivery.”

Tayfun Yildirim has already had good experiences with Muller Martini finishing machines as well as with the after sales service from Pasifik, Muller Martini’s representatives in Turkey. The Martini perfect binder, which was purchased as a used machine, is still producing 7000 soft cover books per hour, even after decades in operation. Last year it was linked to a Floorveyor transport system with a new Merit three-knife trimmer and CB-16 book counter stapler. In 2003 an AmigoPlus perfect binder was added and in the following year a Presto saddle stitcher. “Therefore it was obvious to me,” explains Tayfun Yildirim, “that the press delivery system had to come from Muller Martini.”

The fact that the Vivo, which started production in May 2006, runs reliably proves particularly advantageous for Tuna in the summer months. In June and August, the company, which prints on around 5000 tonnes of paper annually, produces school books for the Ministry of Education seven days a week in three-shift production. These make up 90% of Tuna’s soft cover production. Tayfun Yildirim has expressed his aim to carry out more jobs for the government. “In order to be able to this, we must be able to deliver excellent quality in the shortest time. This is why we are constantly increasing automation.”

The remaining books and magazines are published by the company themselves. Tuna does not produce for third party customers although jobs are passed onto other companies due to capacity reasons. The fact that the signatures leave the printing house in bundles greatly facilitates finishing them for the partner companies.

Özgür Karaca (right), Managing Director at Koza Yayin Dağitim: “With the Vivo we have increased productivity and saved a great amount of space.” Left Machine Operator Sadik Dinlemez.

Koza Yayin Dağitim: Neat Bundles and Simple Operation
Koza Yayin Dağitim was founded in 1987 by Özgür Karaca’s father and employs around 70 staff. He estimates that his perfect binding line has increased efficiency by 15% thanks to the bundle stacker.

One reason for the increased performance is the perfect Vivo bundles. Another reason is that Koza has been printing the signatures for school books in house, meaning that not only do they have shorter distances, but they also have full control over the entire production process – both in terms of quality and deadlines.

Before the investment in the new printing press, these jobs were passed onto a partner company. “When we started production with the new press it was clear,” explains Özgür Karaca, “that we could no longer take off the signatures by hand. We needed a bundle stacker. This increased both productivity and saved us a great amount of space because we no longer needed so many pallets.”

In addition to two used older model machines (a Pony perfect binder and a 221 saddle stitcher), the Vivo is the latest Muller Martini machine at Koza. “We asked around in the industry,” says Özgür Karaca, “and quickly established that there are no valid alternatives to the Muller Martini bundle stacker.” In addition to the neat bundles, the company boss particularly appreciates its simple operation. “Although our machine operators had never worked on a bundle stacker before, they quickly had the Vivo under control after quick training from the Pasifik technicians.” Whilst Özgür Karaca does not operate the Vivo himself, he is fascinated by the technology: “I have great fun watching the machine.”

High performance in the summer months is also required from the Vivo at Koza Yayin Dağitim. Of the 2500 tonnes of paper which they print on, 2000 tonnes are produced in the school book high season. At this time all the machines run the whole week long in three shifts. “Without our bundle stacker,” explains Yayin Dağitim, “we would not be able to complete the jobs for the government.” In addition, Koza also publishes numerous books and magazines in their publishing house and even produces for other publishers. 

Ada Printing Publishing: Step by Step Expansion
Ada Printing Publishing only installed its first printing press a few months ago. “We are expanding our business step by step,” says company owner M. Abbas çarhoğlu. He founded the Dörtel publishing company in 1992 and then eight years later Ada. Together they employee 50 personnel.

Ada started production in 2000 with a perfect binding line from another manufacturer. A Muller Martini Ventura book sewing machine followed in 2003. This year the businesses also entered the printing business. Just a few weeks after the press was installed, printing 40 000 copies per hour, the Vivo also started production. “Afterwards we saw,” explains M. Abbas çarhoğlu, “an increase of at least 10% on the perfect binding line.”

The fact that job volumes at Ada quickly increased (on peak days during the school book season, 25 tonnes of paper are printed on in three-shift production) is not least due to the automated press delivery system. “I have known Muller Martini for many years. That’s why it was so easy for me to choose the Vivo,” says M. Abbas çarhoğlu. “Furthermore, I had seen it in operation in other businesses. I particularly liked its simple operation.”

Ada solely produces for other publishers. Their biggest customer is the Ministry of Education with their school books. Then there are publishers which are mostly from the Ankara area, but some are also from other towns in Turkey. Ada also prints tabloid newspapers for trade unions using the coldset process. They soon plan to enter the magazine and inserts business. “But in able to do this,” says M. Abbas çarhoğlu, “we first have to invest in a new heatset printing press.”

Ministry of Education: The Vivo as Bearer of Secrets
The fourth new Vivo has been in operation in a special location in Ankara since last July. At a special office of the Ministry of Education, 44 members of staff only print products with extremely volatile content. Every year seven million exam papers – for students and professionals in further study – are printed and stitched in a location clouded in mystery. The maximum length for each exam is 2 signatures of 16 pages – but with different page orders to make cheating more difficult. “Top secret” is the order of the day for the whole building. Even the unsuspicious «Panorama» Team from neutral Switzerland was not allowed to enter the machine park.

“Up until this summer we took off the signatures by hand,” says Mustafa Akdaş, Managing Director Printing and Production of the Ministry of Education. “And you can imagine how long that took us.” The state printers therefore pushed for an automated solution. Mustafa Akdaş: “We visited a few Muller Martini customers and based on their good experiences we decided on the Vivo bundle stacker. This significantly accelerated our production process.”

 

Ten new Vivos in Turkey
In addition to the four Vivos at Tuna, Koza, Ada and the Ministry of Education in Ankara, a further six identical bundle stackers have recently been installed in Turkey. Three were at çaglayan in Izmir, two at Dogan in Istanbul and one at Imaj in Istanbul.