Finishing & Screen Printing

Automation for Efficiency

Tuesday 13. May 2008 - is the new slogan of MB Bäuerle, an innovative company presenting a number of new developments and product enhancements at the drupa 2008.

These benefit the traditional folding products as well as inserting and mailing systems. Todays printing industry is facing an ever increasing need for specialization and expansion beyond purely paper-based media. This makes optimizing and automating processes more important than ever.

The most automated folder available today, prestigeFOLD NET 52, is expanded downward into the specialities of pharmaceutical and small format folding. prestigeFOLD NET 38 will be presented for the first time at the drupa 2008. With NET 38 MB Bäuerle offers an optimum of operator convenience and CIP3/CIP4-compatibility for small format folding. Fully automatic machine set-up, sturdy construction, and a high degree of adaptability round out the outstanding features of this buckle fold machine. With the prestigeFOLD NET 38, different machine configurations for the format range 38 x 65 cm will be exhibited. They feature the same complete automation from feeder to delivery as their big brother prestigeFOLD NET 52. Setting automation is comprehensive including positioning of the setting elements for the flat pile feeder, fold plate stops, deflectors, fold rollers, alignment rails and delivery rollers. These settings take place automatically. Operator guidance is self-explanatory through a touch screen panel. 20 standard folds for parallel and cross folds are programmed. All other folds are easily and quickly programmable. More than 200 jobs can be saved in a program memory. Set-up times for repetitive jobs are extremely short because speed, sheet gap, shingled delivery, etc. are also set automatically. Corrections of the fold are possible with a precision of 0.1 mm while the system is running.
prestigeFOLD NET 52 and 38 systems can be equipped with 1, 2 or 3 buckle fold units, with 2, 4 or 6 automatic fold plates in each fold unit. The addition of a mobile knife fold unit is also possible.
prestigeFOLD NET 38: max. format 38 x 65 cm, min. format 7 x 12 cm, speed 220 m/min.

Besides a classical configuration, the prestigeFOLD NET 52 will be shown in a customized application with JDF-workflow-connection. The Ethernet interface provides CIP3/CIP4-compatibility, enabling integration into in-plant networks. Data transfer for machine set-up and real-time recording and transmission of operating data to remote hosts is now a reality. Customer benefits from this combination of all operational sequences, such as, for example, the reduction of production cycles, improved quality control and less waste, will be shown at the booth of MB Bäuerle. In addition to the advantages resulting from the complete automation of the prestigeFOLD NET 52, the flexibility of this line of products is demonstrated by presenting the folder in a configuration for continuous forms; a two-up self mailer will be produced on-site.
Another highlight is the the Hybrid-Mailer NET 52, a mailing system for processing both cut sheet and continuous forms. This system emphasizes that automation makes sense for the production of mailings. Included in the mailing system is also the fully automatic fold unit NET 52 with front-mounted timed perforating head unit, cutting module CM 52 with timed cutting head and perforating tool, a second NET 52 fold unit with cold glue valves, a vacuum transfer table with hot melt head, plough folding unit and shingled delivery. On the vacuum transfer table a card is glued onto the self mailer with a friction feeder. After card attaching the self mailer is plough-folded and sealed on both sides. A camera systems ensures that the cards and self mailers match.
prestigeFOLD NET 52: max. format 52 x 85 cm, min. format 10 x 12 cm, speed 220 m/min.

With the leaflet folder CAS 21/4 NET, MB Bäuerle exhibits the first completely automated folder integrated in packaging systems for folding pharmaceutical inserts. All important settings are made by touch screen display. Four automatic fold plates with integrated deflectors allow all common small folds. The smallest fold length is 16 mm. 16 folds are programmed and can be recalled immediately, all other folds are easily programmable.
Fold rollers setting has also been automated and code readers move to a defined position by pushing a button. Also by pushing a button the setting data of all jobs can be saved, so precise setting of the system for repetitive jobs is accomplished in a very short time. This increases productivity, making short runs more feasible. An electronic interface permits the integration of the leaflet folder software with the control of the cartoning or packaging machine.
The CAS 21/4 feeder is top-loaded to ensure uninterrupted operation. It is possible to process pre-folded products as well as unfolded sheets.
Not all package inserts must be folded during the packaging process. Operating instructions and information leaflets can, for example, be produced in a separate work stop. For this application MB Bäuerle will show the leaflet folder CAS 21/4 NET as an offline version. For this purpose the fold module is connected to a pressing unit and a tabbing system which close the folded package inserts before they are stacked in the vertical stacker SKM 36.
CAS 21/4 NET: max. format 21,6 x 60 cm, min. format 10 x 8 cm, speed 240 m/min.

The folders of the model range CAS 35 make folding professional because the computer control replaces most manual set-ups. Operation is very simple, change of jobs extremely fast. The multimaster CAS 35 is the perfect folder for in-house printing departments, copy and letter shops as well as digital printers. The fold unit is equipped with two fold plates for all common parallel folds. Cross fold jobs are also possible, because the top-loading, bottom-feed air feeder also separates already folded sheets. There is no need for fold roller setting. Special polyurethane rollers make fold roller setting unnecessary.
multimaster CAS 35: max. format 35 x 54 cm, min. format 5 x 7 cm, speed 160 m/min.

An increase in productivity and throughput are the goal of the continuous development of the innovative inserting autoSET 18, a high-capacity system for inserting individualized documents with selective insert feeding. The standard system handles a very wide range of inserts and envelope styles and formats. Total package thicknesses of up to 10 cm are possible. This is an important advantage when generating documents where information about transactions (e.g. bank statements) is combined with advertising messages. The outstanding features of this system are a high degree of operator convenience, comprehensive automation, complete modularity, low noise emission and modern industrial design. Operation takes place by touch screen. After entering the setting data or recalling an existing job from the memory the setting elements for the feeding system, accumulator, fold unit, document track, envelope loader, enveloping station, sealing station, diverter and on-edge stacker are positioned automatically. The machine can process continuous forms and cut sheet, permits the use of many additional components and offers a high document throughput and a maximum speed of 18,000 cycles/h.