For at den grafiske industri skal kunne opprettholde en mere omkostningseffektiv produksjon i en vanskelig tid, kreves ikke bare en kontinuerlig arbeidsflyt fra pre-press til ferdig produkt og hurtige omstillingssystemer, men også pålitelige maskiner. Pålitelighet er særlig viktig av to årsaker: færre driftsstans og forebygging av dårlig produktkvalitet.

Høy produktivitet og prosessikkerhet har fått større betydning i en tid med åpne marked og globalisering, som igjen fører til større omskiftning av oppdrag. Disse fenomenene har ikke bare innflytelse på den menneskelige faktor, men også på de teknologiske mulighetene i produksjonssystemene.

Kundene kan stole på det automatiske signaturkregistreringssystemet Asir3 på Müller Martinis klebebindelinje. Dette system gjenkjenner ikke bare signaturer, som er ilagt ukorrekt i opptagningsmaskinen, men sikrer også den korrekte signaturrekkefølgen i et produkt, samt garanterer en konsekvent produktkvalitet ved hjelp av Müller Martinis egenutviklede AsirCode programvare.

Many small and medium-sized businesses are very successful thanks to innovative machine solutions, because they are able to react quickly and flexibly to customers’ needs – for example with a Pantera perfect binder from Muller Martini, whose menu options are nearly self-explanatory thanks to the Commander.

Reclam relies on the automatic signature recognition of Asir 3 on its Bolero perfect binding line from Muller Martini, which is operated in three shifts. It not only recognizes incorrectly inserted signatures in the gathering machine, but also ensures the correct sequence of signatures as well as the consistent quality of products thanks to the AsirCode software developed by Muller Martini. “Asir 3 gives us 100 percent reliability,” says Franz Dengler.

Lower Unit Costs Thanks to a Higher Level of Automation

In addition to reliable control systems, fully automated production lines also contribute to a higher net output that has a positive effect on company earnings. That goes for large bookbinderies just as it does for niche businesses. “It is precisely in times of economic difficulty that we need highly automated systems,” says José Pinto, owner of Greca Artes Gráficas in Porto, which employs a staff of 40. Despite the difficult economic situation in Portugal, Greca invested in a Presto E90 saddle stitcher and a Pantera perfect binder, two solutions from Muller Martini. “With fully automated systems I can reduce my unit costs,” says José Pinto. “This allows me to increase productivity and makes our company more competitive in the market.”

Thanks to innovative machine solutions, many small and medium-sized businesses are very successful, because they are able to react quickly and flexibly to customers’ needs. “We used to produce only 1,000 softcover books per shift,” recalls Daniel Majdiš, head of production and technology at alfaPRINT in Martin, Slovakia, a company with 65 employees. “Now, using the Pantera, we make at least 2,000 books – per hour!” That means a stunning 1,600-percent increase in productivity. As a welcome consequence, they have been able to regain all the customers they had lost because of large production delays and the associated waiting times before the new perfect binder was commissioned.

Even the JKJ Bokbinderi AB in Falköping, Sweden, which has a staff of only 10 employees, produces roughly 50 percent more softcover products thanks to a new Pantera machine. “We have managed to increase the number of orders on hand despite the difficult times,” comment the company owners Jimmy and Johan Ahlrik. JKJ not only increased its customer base but also, in particular, its reliability and flexibility. “That is especially important, because we cover a wide range of print runs – from 500 up to 300,000 copies per job. This means we need to change over the perfect binding line up to six times each day. Now it goes a lot faster.”

Regular Service Ensures High Investment Protection

In addition to new investments, regular maintenance and updates are also an integral part in maintaining a high level of productivity and profitability. This ensures a high level of availability in production systems that graphic design businesses now depend on due to significant pricing pressure and increasingly tighter deadlines. The fact that machines can maintain a high level of production even years after being commissioned can be seen in the example of the Tempo saddle stitcher from Muller Martini which was installed in 1997 at HeiRa GmbH in Gernsheim, Germany, one of the largest saddle stitching and finishing businesses in Europe. The company will stitch its one billionth magazine on the machine around the time of this year’s drupa.

According to technical manager Peter Dickler, the only reason why it is possible to have an average annual output of 65 million, a maximum monthly rate of 7,905 million and a daily maximum output of 400,000 is “because we have upgraded or replaced many of the machine’s components over the years and because our machine operators make their contribution by ensuring the machines constantly maintain their high level of availability through preventive measures.”

Since thorough and sound staff training as well as regular maintenance is essential to ensuring a high level of investment protection and good return on investment, Muller Martini has standardized its service package under the label MMServices, which features seven modules. “We provide an extensive service, increase the service life of equipment and make existing equipment suitable for new product ideas and markets using expansion options. For new investments, we create real added value with intelligently linked cutting-edge technology for our customers; and for existing machines, we increase the earning power of our customers with specific measures for a higher level of availability,” says Bruno Müller, CEO of Muller Martini.