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How to Increase Your Productivity with a Palletizer

Do you want to reduce the number of man-hours you spend on saddle stitching by half? "Impossible," you will say – "very possible," is the answer from Muller Martini. It is true that palletizers are mainly used behind softcover and hardcover lines. But this topic has long been a hot topic in the saddle stitching sector as well and is becoming increasingly important.
Upgrading your existing saddle stitcher line with a palletizer from Solema will bring you several benefits.

Benefit 1 – more continuous production flow

You increase the automation of your production – not only an omnipresent trend that has a massive impact, especially in three-shift operation, but also a response to the major challenge in the graphic arts industry of finding well-qualified personnel. The use of a palletizer is particularly worthwhile for repetitive processes. This is because setting up the entire system at the push of a button (keyword: Zero Make Ready) ensures a more continuous production flow, more stable production, higher net output and significantly less waste.

Benefit 2 – faster production

You also increase production reliability and production speed. If you operate a saddle stitcher line without a palletizer and with one person at the system, this person is responsible for loading the sheets and unloading the finished products – with the consequence that you produce more slowly. Alternatively, you may have several people at the machine for loading and unloading – resulting in both higher costs and a higher risk of downtime.

Benefit 3 – Reducing the workload of your employees

Your operators can unload and palletize up to 15 tons of paper per shift at a saddle stitcher – all by hand. With a palletizer, you minimize the manual movement of these tonnages. Your employees will owe it to you.

Benefit 4 – ROI in less than three years

You will need significantly less personnel. A calculation example shows how quickly your investment in a Solema machine pays for itself. You are using a Muller Martini saddle stitcher in three shifts with a production speed of between 8,000 and 10,000 cycles per hour, as well as a Solema MiniPluton that produces 15 bundles per minute. Before the palletizer was installed, you needed two machine operators per shift for the complete line – in other words, six machine operators per day. With 50 working weeks, this corresponds to 14,400 man hours. After commissioning the palletizer, one machine operator per shift is sufficient for the complete line – i.e. three machine operators per day. With 50 work weeks, you reduce your man hours to 7200. Depending on the number of shifts and the costs for your machine operators, you can achieve a return on investment in less than three years.

Want to know how quickly you can amortize a palletizer on your saddle stitcher? Contact us and we will be happy to calculate this together with you!
Also read our detailed blog on this topic!

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