Operations Manager at Berlin Industries, William R. McFarland, and his boss Michael Sebring (Vice President of Operations) completed a five-day technology tour around Germany and Switzerland. During McFarland’s European tour, he visited seven renowned graphics companies as well as the Muller Martini Training Center in Oftringen in Switzerland. This trip allowed them to see first hand the latest Muller Martini saddle stitching systems and automated bundle and print roll systems under live operating conditions. “We had a demanding schedule but it was certainly worth it – I was extremely pleased with what I saw,” recalls Bill McFarland.

From left: Bill McFarland (Operations Manager), Rene Campos (Lead Operator Saddle Stitching) and Nick Fatigato (Operations Assistant Manager), together with Peter Doyle (Product Manager Muller Martini USA) in front of the new Tempo 22 high-performance saddle stitcher at Berlin Industries in Carol Stream, USA.

Runs Of Up To 11 Million
The reason behind Bill McFarland’s jam-packed tour of Europe was to evaluate a new high-performance saddle stitcher. Berlin Industries, founded in 1919, has over 60,000 m2 of production halls in Carol Stream, where – in addition to nine printing presses – it already has ten saddle stitchers from another manufacturer. However, these saddle stitchers are all machines from a lower performance segment. “We needed a very productive, high-speed solution,” explains Nick Fatigato, Operations Assistant Manager.

A view supported by the fact that the Chicago-based family-owned business employs a 250-strong workforce in its 24/7 operation and prints and stitches advertising magazines and so-called “magalogs” – a cross between a magazine and a catalog – in runs of up to 11 million copies for customers throughout the world. When it came to the lower print runs of up to 50,000 copies, on the other hand, it was a rapid changeover that was called for.

Even the First Job Ran at 22,000 Cycles per Hour
According to Bill McFarland, the Tempo 22 – featuring the new Muller Martini color of laser blue – part of the new generation of saddler stitchers, more than satisfies both requirements. Berlin Industries chose the Tempo 22 not least because of Muller Martini USA's excellent range of services. “Installation went smoothly from the outset – we started production immediately and our first job ran at the maximum speed of 22,000 cycles per hour, so things got off to a perfect start!”

The Muller Martini Tempo 22 is Berlin Industries' first investment in a high-performance saddle stitcher.

Rene Campos, the Lead Operator Saddle Stitching, believes that the efficient startup was due in no small measure to the ten-day training course that he attended together with Nick Fatigato and three machine operators at the Muller Martini Training Center in Switzerland. “The training was extremely valuable, especially as I had no previous experience of working with Muller Martini systems. The instructors dedicated plenty of time to train us, and provided the right answer to every detailed question that was asked, this was particularly important for us because we now also produce at high speeds.”

During the training course, Rene Campos attached great importance to job changeovers, which have a considerable impact on the current day-to-day operations. As he points out: “Thanks to the simple set-up of the Tempo 22 line with its three-knife trimmer and Robusto stacker we need half as much time as we do for the other saddle stitchers, which is another reason why we are thrilled with our new saddle stitcher,” emphasizes Rene Campos.

High Quality Even at High Speed
Even at high production speeds, according to Bill McFarland, the new Tempo 22 with stream feeders, six feeders, cover feeder, card gluer and subsequent inkjet addressing not only runs constantly, but also ensures that the printed products are of a high quality. And for Berlin Industries this is just as important as meeting increasingly tighter deadlines. The family-run business is one of just five companies and the first web printer to bear the quality seal of the exclusive G7 Color Certified Master Printers which, thanks to a special prepress technology, is able to guarantee extremely high color quality.