Tech Watch

Tech Watch: The Matrix from Vivid Laminating

June 14, 2017

by Lara Copeland, assistant editor, PostPress

The Matrix series is from Vivid Laminating Technologies Ltd., Coalville, England.

Specialty effects is a popular trend in short- to medium-run digital printing. The Matrix series from Vivid Laminating Technologies Ltd., Coalville, England, features multifunctionality to do foiling, holographic effects and spot UV effects that are easy to apply without costly dies or setups.

“For many years, luxury packaging with special-effect foils and finishes was only available to the biggest and most successful companies,” explained Jon Gasperini, vice president North American sales. “However, today these effects are within reach for even the smallest boutique business.” The same holds true for many other special and unique effects such as labels with glitter holographic lettering, foiled wedding invitations, variable data mailers and rainbow holographic security print for event ticketing. Printers of all sizes can offer their customers these products and produce them in house with quick turn time.

The Matrix can be used for short-run variable data foil fusing using DataBind FuseEffects® thermal transfer foils. Thermal transfer foiling can be applied to any digitally printed stock using the Matrix. Foiling can be done direct on coated stock, on specially treated soft-touch matte laminate or on printable glossy laminate, allowing low-cost creative designs for business cards, invitations, direct mail, brochures and more.

Vivid’s Matrix also brings lamination in house, giving a company control over timing and quality of output when finishing a job. With an easy-to-use multilingual digital control panel, the user can quickly set up for small runs or accommodate large runs. The Matrix can conservatively run 750 (12×18″) single-sided cover sheets per hour and with all types of laminating film. Average cost to run a 12×18″ sheet can be as low as 2.5 cents for single-sided gloss, or the popular silky or soft-touch mattes will average about 11 cents a sheet. “Bringing lamination and foiling in house saves time and money, while also creating the opportunity to deliver additional custom products,” Scott Diamond, manager lamination sales and service, commented.

The Matrix also has a self-registering gate that ensures proper and consistent spacing of sheets, maintaining underlap for single-sided laminating or a consistent gap if doing a two-sided sheet. In conjunction with the automated burster, the laminator delivers a consistent output for the next step of production – be it creasing, folding or cutting.

Several options are available when doing smaller singled-sided sheets. A film trimmer allows the user to slit down a roll if only working with a wider roll, and a take-up mandrel is available for doing variable spot foiling using DataBind FuseEffects® thermal transfer foil. An auto feeder also is available, mounting directly on the feed table, as is a rotary blade cutter for cutting thicker materials that won’t burst inline.

“We have seen our customers achieve new levels of success when they realize not only are they saving time and money by laminating in house but also are increasing profits by offering these new specialty effect products to customers directly,” said Gasperini.

Technical Details

The Vivid Matrix is available in two sizes: the MX-370, which can accommodate 1″ film and a 17″ sheet width; and the MX-530, which can accommodate 20″ film and a 22″ sheet width. All the MX series machines are manufactured with a large, chromed-steel heated roller offering a quick warm-up time of 10 minutes. The metal roller solves difficult output issues when running hard-to-laminate digital prints by applying direct heat and pressure simultaneously, allowing laminating at a lower temperature in conjunction with the pressure of the pneumatic roller to run faster. Both systems are available with manual or pneumatic roller pressure, single-sided or double-sided, and with a heated bottom roller and lower supply mandrel.

Tech Watch: Gietz’s ROFO 910 PLUS Hot Foil Machine

March 10, 2017

by Lara Copeland, assistant editor, PostPress

Since 1892, Gietz, Gossau SG, Switzerland, has supplied the printing and packaging industry with high-performance machines. The company builds its machines exclusively in Switzerland before they are delivered worldwide. Recently, the company upgraded the ROFO foil stamping series that was first introduced over a decade ago. The 36″ width ROFO PLUS flexible web machine was upgraded for improved performance of wide web applications. “The Gietz ROFO 910 PLUS is specifically designed for the requirements of foil stamping and blind embossing,” noted Steve Leibin, executive vice president of business development for Matik, the exclusive North American distributor for Gietz. The ROFO series from Gietz offers flat-flat hot foil stamping, embossing and hologram application capabilities for web-fed applications.

The stamping and foil transfer is performed by a toggle-operated platen press by means of flat stamping dies. This principle allows a versatile application of the machine, a minimal consumption of foils and the use of low-cost tools. Used in the print finishing of printed and plain web substrates, it enhances the value of flexible packaging, gift wrapping, chocolate and shopping bags, and cigarette packs. The 910 PLUS also is well-suited to the security industry for its ability to add holograms on currency and security applications. “Hot foil and holograms are being applied on PET, PP, PC, laminated films and thin paper substrates, which are impossible on traditional sheet-fed machines. Plus, the web-fed process enhances profitability,” explained Leibin.

The machine demonstrates its flexible performance range by processing paper, cardboard, plastic films and composite substrates. “It also includes many features exclusive to Gietz, such as the VACUFOIL high-speed foil transport system; multiple, fully adjustable dwell settings to optimize time under pressure for hot foil stamping; both longitudinal and transverse foil feed; short set-up times and modular flexibility,” Leibin revealed. One advantage for the hot foil stamping “flat-flat principle” is the deep reliefs. It also allows structure and micro embossing, in addition to a combination of foiling and embossing, at one time. Up to eight foil feeds are available and, therefore, eight registered hologram webs also are available.

“The ROFO 910 PLUS can add value to flexible packaging, film and paper applications that are challenging or impossible for sheet-fed machines,” continued Leibin. Additionally, due to the modular construction, it is possible for tailor-made customer solutions. The machine can be configured with optional sheeting, stacking, slitting or diecutting capabilities for inline production efficiencies.

In other packaging markets – such as label and folding carton – the added value that hot foil offers is well recognized; however, it is not well known or often utilized in the flexible packaging segment. As Leibin pointed out, “pouches are becoming common on store shelves. Hot foil on pouches enhances the value of the product and helps that pouch jump off the shelf at the moment of truth in the shopping aisle.”

Gietz customers offering hot foil stamping and hologram capabilities in the flexible packaging market are experiencing “excellent growth by offering further innovation to this fast-growing market,” Leibin reported. He said customers have purchased second ROFO machines or added multiple stamping units in a single ROFO line to achieve creative solutions with greater profitability. “Customers are excited by the unique and superior capabilities they can offer their customers,” exclaimed Leibin.

Technical Details

The maximum substrate web width for the ROFO 910 PLUS is 35.8″. Its maximum substrate weight is 300g/m² and the minimum paper weight is 40g/m², with the option to handle very thin film substrates as low as 12 micron PET. The continuous substrate web pull maximum is 800mm/31.5″ and its minimum is 50mm/2″. The machine’s stamping area is at a maximum of 31.5×28.3″ (800x720mm). It has a new maximum speed of 393″/min (120m/min) and up to 10,000 strokes/hr. The maximum pressure of the press is 165 US tons.

The ROFO 910 PLUS weighs approximately 18.2 US tons with its base measuring approximately 37.7×13.5″(11.5×4.1m), while the height reaches 11.8″ (3.6 m). The standard equipment includes VACUFOIL foil transportation system, two longitudinal foil feeds, high-capacity baling press for waste foils and touchscreen machine control. Optional equipment can include up to 10 foil feeds (eight longitudinal and two transverse) and hologram equipment up to eight foil webs. The ROFO series also is available in 750mm and 1020mm web widths.

Rollem International’s Insignia 7 Diecutter

December 9, 2016

by Lara Copeland, assistant editor, PostPress

The Insignia 7 Diecutter from Rollem International, headquartered in Anaheim, California, is a sheet-fed, rotary, flexo-magnetic machine designed to meet the shorter to long run, on-demand needs of the packaging and label market segments of the printing industry. Susan Corwin, marketing manager for Rollem International, noted that the setup and changeover processes are simple and quick. “The processes do not require a high degree of skill, as called for by the larger flatbed style diecutting machines seen previously,” she said. This ease of setup fills a niche for customized, craft packaging, prototyping, limited-run products and more.

The Insignia functions on purely mechanical timing and movement throughout the machine, which ensures greater reliability than dependence on servo motor and electric timing. Sheet after sheet, the guide and gripper registration system ensures 100-percent cutting accuracy. This finishing solution is suitable for both commercial offset and digital printers. “The Insignia provides a tremendous amount of flexibility to owners of the system,” Corwin commented. The addition of the rotary diecutter allows for more avenues of income, such as short-run folded cartons, customized labels and pocket folders, door hangers, POP displays, shaped invitations and more. Corwin added, “The flexibility in setup and changeover translates into the ability to offer and fulfill many different SKUs and shapes for products.”

Built to meet the specific requirements of its customers, the Insignia system is semi-customizable; it is offered with single or dual magnetic cylinders. “The single magnetic system is recommended for pressure-sensitive label work or straight diecutting,” Corwin stated. These systems are commonly used for applications that do not involve folding, such as kisscutting and straight “crush cut” diecutting. The dual magnetic system utilizes a paired set of male/female dies used for turning packaging products, carton work or presentation folders. This paired male/female set of dies translates into no makeready, only requiring switching the sets of dies between jobs.

Single magnetic machines have the option of being a bearer system or a non-bearer system, whereas dual magnetic machines always will come as a bearer system. With a non-bearer machine, the operator has the flexibility to use a die tool to kisscut varying thickness of adhesive liner as the operator physically adjusts the gap between the cylinders. On the other hand, a bearer configuration – available for thicker substrates – provides a floor for the cylinders to run against, creating a fixed gap between the cylinders. Corwin explained that this prevents an operator from accidentally crushing or damaging a die tool, while also providing stability in the cutting station. Bearer cylinders are at a fixed gap and cannot be adjusted. One die can be used to diecut across all thicknesses of material; however, different die tools are required for stock thickness changes and channel scoring.

Two optional delivery systems are available for the Insignia. A waste stripping unit removes the cut pieces from the matrix or skeleton of the cut sheet. “The ability to remove a hanger hole, or sombrero hole, from finished, cut pieces means eliminating a manual labor choke point in production lines,” Corwin said. She further explained that being able to batch count finished, stripped product on the back end of the system allows for a more streamlined collection and fulfillment of orders. The Insignia also can run inline with Rollem’s folding/gluing unit for any box or packaging work. The Insignia will cut product, strip the waste material and feed cut products directly into a folder/gluer unit for “printed sheet to folded/glued box” production utilizing a single operator.

“The Insignia7 has been well received by both existing packaging companies seeking quick changeovers and traditional printers and marketers seeking entry into the expanding consumer packaging market,” reported Corwin.

Technical Details:

The Insignia7 weighs 4,800lb and has a footprint of 79x58x55″ (200x147x140cm), not including delivery. It is offered in either a single upper magnetic cylinder configuration, lower hardened anvil cylinder configuration or a dual upper and lower magnetic configuration.

The Insignia7 has a feed capacity up to 40″ (101cm). It offers the largest sheet size available in the rotary diecutting class, featuring the B2 sheet capacity of 30×24″ and run speeds of up to 5,000 sheets per hour.

Sheet sizes range from a minimum of 8×8″ (20x20cm) to a maximum of 30×24″ (76x61cm). Material thickness ranges from a minimum 2pt (40-60gsm) to a maximum 24pt (430-450gsm) cardstock.

Book Automation’s Universe Sewing WEB-FED Book Production Solution

September 6, 2016

by Lara Copeland, assistant editor, PostPress

The Universe Sewing WEB-FED Automatic Book Folding and Sewing Line from Book Automation, New Milford, Connecticut, is a roll-to-book solution allows for high-quality, lay-flat digital book production for sewing books directly from the printed roll.

Specializing in design and production of high-quality book sewing machinery since 1979, Meccanotecnica, along with its New Milford, Connecticut-based service and support division, Book Automation, recently released its new Universe Sewing WEB-FED Automatic Book Folding and Sewing Line. This roll-to-book solution allows for high-quality, lay-flat digital book production for sewing books directly from the printed roll. Manrico Caglioni, president of Book Automation, said “The Universe Sewing WEB-FED automatic folding and sewing line represents a game changer in the digital book printing industry.”

In a digital environment, the machines help users to efficiently manage short- to medium-run lengths and streamline production. “The solution is a breakthrough,” according to Caglioni, “because it gives printers the ability to effectively manage the cost of medium runs.” It also is ideal for offset printers wanting to invest in digital printing and top quality finishing systems – allowing users to avoid certain steps, like creating printing plates, folding, palletizing and gathering signatures.

The Universe Sewing WEB-FED performs several processes in a single run including unwinding, cutting, sheet buffering and feeding, scoring and folding, collating and sewing. Guaranteeing a constant stream towards the Universe Sewing, the buffer module collects sheets from the webcutter. A new registering device squares the sheets before they are transferred into a scoring station where they are then folded into “four-pages” and collated to compose a signature. The new pressing roller guide feature provides perfect folding and ensures the best alignment of the folded sheets in the collating unit. Signatures are then transferred under a PC programmable accelerator wheel and conveyed to the sewing unit. Book blocks are automatically separated from each other and delivered spine up for easy unloading. The line’s model showcases a 15″ touchscreen and a Siemens PC that controls all functions. Machines are enabled for remote service connections and live support performed by expert engineers.

Optional elements are available upon request and include a device that reduces thread ends to around 10mm, the GigaLynx dual control camera for controlling the sequence by reading barcodes or images and an ionizing unit that removes the potential electrostatic charge on sheets. Universe Sewing can operate standalone, nearline or directly connected to inline – book finishing lines.

The Universe WEB-FED sewing line can be operated by a single person, providing users the benefit of cost-effective production and low operating costs. Additionally, this technology gives digital printers the ability to use thread sewing as a binding technique. Its inherent properties give this solution yet another advantage for the user. Caglioni explained further saying, “The lay-flat feature is a natural attribute and not a matter of machine settings, operator skill or ability. Superior resistance and longevity make it last for generations.” Furthermore, a significant feature for print-on-demand is the fact that the quality of a sewn book can be validated and checked as soon as it comes out of the production line. Other binding methods require books to be left overnight before finishing, ultimately increasing the lead time.

Customer and prospect response to the unveiling of the new solution has been positive according to Caglioni, who emphasized, “Digital printing has reached good quality and definition along with high production levels that are increasingly reaching the cross over point between digital and offset printing technology.” With digital printing not being confined to short runs anymore, there is a need to better manage the production of books in medium runs.

Technical Details

The Universe Sewing WEB-FED Automatic Book Folding and Sewing Line can handle a maximum sheet feeding speed of 400 A3 sheets/min and a maximum folded signature thickness of 3mm (?”). There are 10 stitch positions and a stitch length of 19mm (¾”). The external supply of air consumption is 250 l/min at 7bar, and its net weight is 2,900kg.The sheet buffer has a minimum sheet size of 210x270mm (8 ½x10 ¾”) and a maximum sheet size of 340x464mm (13 ¼x 18 ¼”).

Tech Watch: B&R Moll’s digi-mollPAK System

June 17, 2016

by Lara Copeland, assistant editor, PostPress

The digi-mollPAK System from B&R Moll, Inc., Warminster, Pennsylvania, is a compact inline folder-gluer.

As an industry supplier of folder-gluers and specialized bindery finishing equipment for printing and packaging facilities, B&R Moll, Inc., Warminster, Pennsylvania, recently developed the digi-mollPAK System. Like all B&R Moll machines, this compact inline folder-gluer is made almost exclusively in the US. It provides digital and commercial printers with fast, flexible performance for complex packaging projects. Cartons, pillow packs, room key sleeves and presentation folders are just a few examples of the variety of applications the new unit can handle.

According to vice president of sales for B&R Moll, Inc., Kevin Moll, “The digi-mollPAK System incorporates many proven folding and feeding mechanisms developed by B&R Moll.” These mechanisms include an open format system that facilitates quick changeover between jobs and a dual-stream capacity to enable multiple feeds. Positive feed control is provided by a bottom friction feeder that not only offers continuous feed for regular stocks but also irregularly-shaped materials. The system’s workflow is maintained by a tipper plate with an air blast attachment, movable belts and pans, and anti-marking formers. Additionally, the system’s liftgate can be adjusted to allow for a quick job set-up.

“We developed the digi-mollPAK System specifically for digital printers who needed a fast, flexible inline folder-gluer that could deliver complex packaging jobs at an affordable price,” Moll explained. He elaborated by reporting that customers have been responding well to the new system. They are pleased with the drastic reduction in set-up and changeover times as compared to their big, inline folder-gluers. “It allows them to get more jobs in and out in a day. It also gives them more flexibility and allows for the acceptance of other work they would normally say ‘no’ to,” Moll revealed.

Customers also appreciate the footprint of the machine and the amount of flexibility it has. “It allows customers not only to just convert their packaging work, but their commercial print work as well, such as pocket folders, mailers and taping projects,” Moll stated. The system works well with other presses, and Moll considers it the perfect complement to a digital press, as well as a commercial press. The digi-mollPAK system’s efficiency for specific jobs is increased by accessories that include an inserting attachment, tape head/silicone head, vacuum belt system and a trombone feed assembly.

Technical details

The compact B&R Moll digi-mollPAK System has a linear footprint of just 15′ and handles material ranging from 70lb cover to 28pt. stocks (140-500g/m²) in sizes ranging from 2×4″ (50x102mm) up to 36×20″ (914x508mm).

Maximum linear speed is 425’/min (130m/min). The system is available with either 220V 3-phase, 60A/60Hz or 400V 3-phase, 60A/50Hz power connections and a 90psi (0.7mPa) compressed air connection.

Tech Watch: Duplo USA Corporation’s 600i Booklet System

March 11, 2016

by Lara Copeland, assistant editor, PostPress

The 600i Booklet System from Duplo USA Corporation, Santa Ana, California, is a high-end collating and bookletmaking solution that integrates the fully automatic DBM-600 Bookletmaker with high-speed DSC-10/60i Suction Collators.

Duplo USA Corporation, a provider of digital print finishing equipment in Santa Ana, California, has unveiled the new 600i Booklet System, a high-end collating and bookletmaking solution that integrates the fully automatic DBM-600 Bookletmaker with high-speed DSC-10/60i Suction Collators. The customizable system features automated simplicity and intelligent bin feeding, and it is ideal for letter landscape applications.

According to Duplo USA Production Manager Anthony Gandara, “The DBM-600 Bookletmaker is an example of Duplo’s efforts to improve its current products and to create innovative solutions to help our customers.” He noted that the improved bookletmaker has faster processing speeds and can process a larger paper size, which allows customers to perform a wider range of bookletmaking applications, including letter landscape, calendar, CD-size and small booklets. Additionally, the newer system can process small paper sizes without requiring a special kit or accessories.

The 600i Booklet System features the Duplo PC Controller software to program and manage the entire system. From a PC, a single operator can use the intuitive Graphical User Interface (GUI) for faster and easier job changeovers. After paper sizes are selected, the PC controller automatically calculates the stitch, fold, and trim positions, while the user-friendly interface elements allow the operator to select settings and make adjustments, if needed. According to Gandara, the operator can “program and save an unlimited number of jobs,” and “change from one job to another within a matter of seconds, without any tools, simply by selecting and recalling the saved job parameters and setting the automatic changeover of the entire system.”

The 600i Booklet System comes standard with the ability to perform a variety of booklet-type applications, including saddlestitch and fold, saddlestitch no fold, fold only, six-page insert, side stitch, side stitch and fold, corner stitch, and corner stitch and fold. To meet the individual needs of each customer, there also are customizable options; for example, booklet production can be doubled for certain applications by adding the 4-Stitch Head Kit and the DKT-200 Two-Knife Trimmer and Gutter Cutter module to enable 2-up bookletmaking. Producing flat, square spine booklets is another option when the ASM-500 Square Spine is added to the system. With this customization, Gandara reported Duplos fifth generation automatic bookletmaker “has had a positive reception from both existing and new customers.”

Technical Details

The DSC-10/60i Collator can handle paper with a width of 4.1″-14″ and length of 5.8″-24″ and various weights for two different types of paper. Fine quality paper can weigh between 52-157gsm, and art-coated paper can weigh between 79-157gsm. It has a bin capacity of 2.6″. The DBM-600 can make 5,200 booklet sets per hour, compared to 5,000 sets per hour in the former model, the DBM-500. The DSC-10/60i Collator also can stack up to 10,000 sets per hour. It measures 34″x33″x78″ and weighs 674lb.

The 831lb DBM-600 Booklet maker is 73″x37″x31″ and comes standard with two stitcher heads. Its maximum sheet size is 14.33″x25x19″; minimum is 4.13″-6.69.” It has folding capacity up to 30 sheets (thickness: .11″/3.0mm) and stitching capacity up to 50 sheets (thickness: .19″/5.0mm).

Tech Watch: KAMA ProCut 76, Absolute Printing Equipment

December 14, 2015

by Brittany Willes, PostPress

The KAMA Automatic Die Cutter ProCut 76 is available from Absolute Printing Equipment Service, Indianapolis, Indiana.

This year’s Graph Expo featured many new and exciting products from companies around the world. Among the various technologies on display was the KAMA Automatic Die Cutter ProCut 76 from KAMA. The ProCut 76 was introduced by Absolute Printing Equipment Service, Indianapolis, Indiana, the North American distributor for the KAMA line of diecutters, foil stampers and folder/gluers. Designed with user-friendly features, quick job change and lower setup times, the ProCut 76 serves as a practical solution for printers and packaging manufacturers.

According to Marcus Tralau, CEO of German-based KAMA, “currently we see the industry facing two challenges in postpress: ‘How can we convert digital prints at high quality?’ and ‘How can we arrange for an efficient and profitable short-run production?'” The new generation of the ProCut 76 provides a camera-based AutoRegister for high-register precision for each digital print, as well as a device for inline stripping and blanking. Further benefits of the new system for added value finishing include changeover from diecutting to finishing by hot foil stamping (or optionally hologram) in just a few minutes and a performance of up to 5,500 cycles per hour.

Unique to the ProCut 76 is the Stripping and Blanking Unit with a tool-less design, meaning there is no tooling to buy or maintain and setup can be accomplished in minutes. The programmable feature of the SBU has job storage, allowing seconds to set up repeat jobs. A blow-down device takes care of small to medium holes and waste is shredded for easy disposal. Furthermore, the SBU is equipped with a denesting feature to spread the product apart for easier removal.

The ProCut 76 has been designed to handle a variety of applications using new tools and solutions. For example, the machine is equipped with a universal chase, which can hold dies of any size while allowing fast adjustment using the integrated adjusting device. A prepared mounting plate affixed to a basic plate allows for improved setup times, especially when it comes to repeat orders that require a lot of creasing lines. Additionally, a special chase enables users to mount existing dies on a predrilled chase or a chase with clamping bars.

Thanks to the machine’s improved design, the ProCut 76 is capable of processing a wide variety of materials, including paper and paperboard, cardboard, and micro-corrugated board (including laminated), as well as plastic materials. Further improvements include the AutoRegister, which aligns every sheet to a printing mark with an accuracy of one tenth of a millimeter. The AutoRegister offers diecutting and line creasing, in addition to accurate blind embossing and reliefs for digitally printed sheets. Unlike traditional machines which position by means of the sheet edges, the AutoRegister aligns each sheet to a print mark. A camera captures sheet by sheet the actual print position and servomotors compensate smallest deviations in the positioning. Should a sheet register as out of place, two servo motors allow for quick placement correction both in and across the direction of sheet travel (x and y direction).

An Optical Registration System looks for a target printed with the sheet. According to Larry Hollingsworth, sales representative for Absolute Printing, “It makes no difference what the sheet was printed on as long as the target is printed with the sheet. The ORS finds the target and registers the print to the die at running speeds. Our customers are finding that foiling and embossing jobs are registered perfectly and ‘cherry picking’ for good sheets are a thing of the past.”

Technical Details:

The KAMA ProCut 76 is capable of handling paper, cardboard and plastics materials from 100-800gsm (6-32pts), compared with the KAMA ProCut 58 80-800gsm (4.4-32pts). When using a cardboard kit (optional) or single sheet feeding, the ProCut 76 handles micro flute corrugated board up to 1,500gsm/1.8mm (80pts).

Maximum sheet size is 760x600mm (30×235/8in) with a minimum sheet size of 279x210mm (11×8¼in). Maximum cutting size is 750x590mm (29½x23¼) while the maximum cutting force consists of 165t (180 US tons).

The maximum stacking height for the feeder runs 1,160mm (46in), with the maximum stacking height for the delivery unit at 985mm (39in). The cutter’s minimum gripper margin consists of 10mm (0.4in).

Additionally, the machines maximum performance (dependent on material, size and cutting sheet arrangement) is capable of 5,500 sph. The ProCut has a cutting line height of 23.8mm.

The KAMA ProCut 76 measures 4,870×2,960mm (194¾x106 in) with a net weight of 5,500kg and connecting power of 13kW.

Tech Watch: Aerocut G2 Digital Finishing System

June 17, 2015

by Brittany Willes, PostPress

Aerocut digital finishing systems combine slitting, cutting and creasing into a single operation.

MBM Corporation, Charleston, South Carolina, has unveiled the next generation of Aerocut systems, the Aerocut G2. Aerocut digital finishing systems combine slitting, cutting and creasing into a single operation. The G2 finishing system has operating speeds up to two times faster than the base Aerocut model, while featuring an improved interface and several new functions.

Time loss prevention served as a driving theme for the system. “A dramatic amount of production time is saved using the G2,” said Carrie Ford, art director for MBM. Like the original Aerocut, the G2 merges several finishing functions into a single process. “There is no need to have a separate cutter, slitter or creaser since the G2 is able to do all three in one pass. This not only saves time, but money as well.” Improving on the previous system’s ability to handle up to 12 sheets per minute (based on two cuts and one crease, 8½ x 11″ paper), the G2 produces 20 sheets per minute, which enables users to cut down on manufacturing time. Additionally, the G2’s high-capacity feed tray is able to hold twice as many sheets and is equipped with a three-try re-feed mechanism in which the machine automatically will re-feed the sheet up to three times in case of double feed. Finally, new and improved to the G2 is the ability to cross-perforate by changing out the creasing unit with the cross-perforating unit.

Additional improvements have been made to the color touchscreen interface control module, which has been enlarged for ease of operation and comes pre-programed with 263 cutting templates. The interface’s memory can store up to 60 custom programs, while the new “flex mode” allows for up to 30 additional odd-sized programs to be set up and stored in memory. According to Ford, the G2 also can be equipped with “an Adobe InDesign plug-in, allowing designers to set up jobs and easily transfer templates from their workstations to the G2, saving even more production time,” she said. “In addition to saving time, the air suction feed system and register mark detection sensor ensure accuracy on every job, saving resources as well.”

The Aerocut G2 can slit, cut, crease, score and perforate a variety of jobs, including brochures, business cards, postcards, greeting cards and CD jackets. Furthermore, a range of stocks (such as gloss, laminated, UV-coated and large format) can be creased and scored without cracking, even with full-bleed ink coverage. In order to accommodate various stock sizes, the new machine also includes adjustable magnetic paper guides.

Ford asserted that MBM has received encouraging reviews from customers regarding the new system. “We have had many positive experiences, and we also are starting to see a new trend,” she went on to explain. “With the cost of digital print dropping in the last decade, we are seeing a large increase of small print shops investing in digital print finishing engines. The G2 is becoming the perfect fit for in-plants and small print shops all around.”

Technical Details

The G2 can handle paper sizes 8 ¼x8 ¼” up to 14 3/8×63″ and weight from 32 to 130lbs., though weight may vary due to variations in paper and power supply. The G2’s speed is up to 20 sheets per minute. The feed type consists of belt-drive air suction with a registration tolerance of 0.01″.

Crease depth can be adjusted for different weights of stock with the 5-Position Crease Depth Adjust lever. Maximum creases/cuts per page is 48. Cutting blade is self-sharpening with standard, online perforating units.

With all-metal construction, the G2 is mounted on lockable, heavy-duty casters. The safety access cover ensures the machine will not operate if the cover is left open. The power supply consists of 115V, 60Hz. Dimensions are 32″x36″x43″ with a shipping weight of 452lbs.

Tech Watch: Standard Finishing Horizon RD-4055 Diecutter

March 25, 2015

by Brittany Willes, PostPress

The Horizon RD-4055 rotary diecutter by Standard Finishing Systems was developed in direct response to the rising demand for short-run diecut products.

Standard Finishing Systems, a leading North American distributor of digital duplicating and document finishing products in Andover, Massachusetts, recently has unveiled the Horizon RD-4055 rotary diecutter. Developed in direct response to the rising demand for short-run diecut products, the RD-4055 boasts of simple operation and easy changeover with an intuitive touchscreen that displays easy to understand graphical illustrations for set-up and control.

Neal Swanson, director of marketing communications for Standard, stated the new system, “is a finishing solution that delivers consistent quality from one end of the run to the other.” The RD-4055 is able to diecut, crease, perforate, slit, hole punch and round corner in a single process for digital and offset printed sheets. The vacuum belt feeder allows for superior feeding while the ultrasonic sensor enables double-feed detection on a wide range of substrates. Additionally, a servo motor-controlled “Repeat Register” allows for multiple-up applications from a single die. The only diecutter with this capability, the RD-4055’s register function allows for significantly reduced die cost.

Able to perform simultaneous die- and kisscutting, the RD-4055 can create stickers and labels. Furthermore, the crease function helps prevent image cracking, making it appropriate for boxes, pocket folders and greeting cards that require additional folding after diecutting. According to Swanson, customers have responded positively to the new system. “They are happy with the trouble-free operation of the unit, the wide variety of applications and the very short learning curve,” he said. “They are reporting faster changeover times and greater than anticipated productivity.”

Even small diecuts are “neatly executed; the final result is nothing less than amazing,” remarked Swanson. “I’ve never seen another diecutter finish as many pieces in so short a time. Watching the RD-4055 go through a stack of digitally printed material, while accurately diecutting each unique shape, is eye-opening. The finished pieces seem to roll off the delivery tray in a steady stream.”

The RD-4055 recently was selected as a Must See ‘Ems award winner at the 2014 GRAPH EXPO in Chicago. Chosen by a panel of industry experts, the Must See ‘Ems award acknowledge the most compelling technological advances spanning the entire graphic communications industry.

Technical Details

Feeding, diecutting and separating are achieved in one pass with a speed of 6,000 cycles per hour, making the RD-4055 the fastest in its class. The new system is capable of processing normal paper, coated paper and cardboard. For diecutting, it can handle materials 0.5mm/0.019″. Maximum material thickness for creasing is 0.4 mm/0.015″. The system has single-phase voltage/frequency of 200 to 240v, 50/60hz.

A uniquely designed diecutting section enables quick and easy diesetting. Flexible die plates can be used in thicknesses of either 0.6mm and 0.8 mm/0.0236″ or 0.0315″. Rigid magnetic upper roller and solid lower anvil rollers ensure high-quality diecutting.

Vacuum belt feeding allows for feeding with easy setup and operation. An ultrasonic sensor is used for double feed detection on a wide range of substrates. The RD-4055 is designed to handle sheet sizes ranging from 200x275mm/7.88×10.83″ to 400x550mm/15.74×21.65″ before processing. An optional separator removes the waste from the finished product and delivers it to the waste bin. Finally, a delivery section, supplied with the separator, delivers finished products on a motorized conveyor.

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