Finishing & Screen Printing
The Supra high-performance saddle stitcher: for the best reliability and flexibility
Tuesday 10. June 2008 - For flexible production in the high-performance range, Muller Martini presents the Supra saddle stitcher in combination with the Integro inserting machine: With its new operating concept, motorized adjustment axes and the new Q-stitching heads, this line can be changed over even faster and is even more economical.
When high net output is required, and magazines must be both high quality and individually designed, Muller Martini recommends the Supra high-performance saddle stitcher. It is conceived according to the proven linear principle and produces up to 30,000 copies per hour. It has a modular design and can thus be arranged exactly according to customer needs. The line can be expanded to up to 30 feeders, which makes it especially interesting for selective binding production.
Feeder range for the highest standards
The successful flat pile feeder 416 has been further developed and equipped with innovative accelerating rollers. These permit careful pre-acceleration of the signatures to fifty percent of the gathering chain speed. Feeders can be run in 1:1 or also user-friendly 1:2 loading mode. In 1:2 mode, two feeders share the work and lay the signatures on each second chain pitch. This way, signatures of all opening types can be carefully processed at the highest possible net output and the saddle stitcher speed can be fully utilized.
The sample gluer 423 can be used to increase added value through the application of reply cards, small brochures, product samples or CDs. Its advantages are very easy settings from the outside, ergonomically optimal loading of the feeder hopper, and a signature sticker control. One of its specialties is the gluing of post-its with the same basic sample gluer model. Multiple sample gluers can be put to use in one production line.
By making use of the folder feeder 344, an additional external operation can be eliminated. Cards, single-sheet covers, full covers or multipage signatures can be applied directly to the product. Extremely cost-effective production can be realized with automatic loading using Stream feeders.
Stitching machine with boxer principle
The gathered signatures are stitched in alternation with two stitching units. Both stitching units work using the boxer principle. This means, they counter-oscillate and thus offset the inert force. A stitching unit stitches each second product. Stitching speed is halved this way and the machine can work calmly and thus generates very little vibration.
Stitching is done according to the Muller Martini principle of “flying stitching heads” with the new, revolutionary Q stitching heads (quick set-up). Changeover times were reduced significantly with these stitching heads. In addition, with the new Q-stitching heads, very fine wire can be processed (instead of 0.55 mm diameter 25 grade wire, now new: 0.45 mm diameter 27 grade wire). This reduces the consumption of wire by about one third. Thus costs are lowered and the environment benefits.
Supratrimmer for the best performance
Muller Martini developed the Supratrimmer especially for the high-performance range. Products are precisely lined up in the infeed and conveyed through the trimming process with a double gripper. The upper and lower knives, arranged on cranks, trim products of up to 13 mm thickness at full speed. Because of the scissor-cut arrangement of the knives, outstanding trim quality is achieved and a high knife life is achieved. The Supratrimmer can be set up quickly. The large sliding doors made of plexiglas allow the machine operator an optimal overview and easy access to the knife elements.
Inserting with the Integro
The Integro inserting machine can be fed while attached directly to the Supratrimmer or fed with a conveyor. It works with two overlapping gathering channels inclined at 15°. This ergonomic and clear arrangement allows quick and easy access to the process. Thanks to the inclined infeed of the main sections and the small chain pitch in the gathering channels, the products are smoothly and carefully provided with inserts even at the highest production speeds (up to 30,000 cycles/hour). Because of the automatic pre-adjustment of main section conveyors, channel width and product thicknesses, the shortest job changeover times can be achieved.
Because of the modular Muller Martini design, it is possible to expand or retrofit the system with inkjet addressing, stacker, film wrapper, shrink tunnel and automatic palletizer at any time.
New standardized controls for reliable production
The Supra has the new standardized Muller Martini Automation Platform (MMAP) which provides an optimal overview of the entire production flow. The simple operating philosophy with one central touchscreen and local operating units (HMI) ensures short distances to the controls and thus also quicker set-up and changeover times. The central touchscreen provides the operator with an overview of the statuses of all the machines. Status notices and operating instructions can be accessed directly. Additionally, fine adjustments can be made on the local operating units while the machine is running.
The high level of automation in the Supra line (up to 40 axes, installed from the feeder area to the stacker, can be automatically set up) ensures the quickest set-up and changeover times. The comprehensive quality controls guarantee excellent stitching and trim quality. Since the Supra is JDF/JMF capable, it can be integrated using the Muller Martini workflow system, Connex, into a companys digital workflow.