Finishing & Screen Printing
Digital book production: from PDF to the finished book in just a few minutes with the SigmaLine
Thursday 05. June 2008 - The book market is going through change: While overall sales figures remain almost constant, the growing diversity of titles is inevitably leading to smaller print runs. The big challenge facing book producers lies in producing these smaller runs profitably. Muller Martini is demonstrating with the SigmaLine a total system with which short runs of books can be produced cost-effectively in high quality and with short delivery times.
The SigmaLine will be presented in the new look at drupa – it is a concave shape in the lower section and convex in the working section. This allows the operator to maintain an ergonomic posture. The doors now have a continuous rod which allows them to be opened more easily, giving even better access to the machine. With the new generation of standardized control systems from Muller Martini, which has been fully implemented on the SigmaLine, the machine is now considerably easier to operate. In order to improve the efficiency of small runs even further, the SigmaLine makes use of the advantages offered by the new Connex workflow system from Muller Martini. In-line book production is based on this continuous JDF/JMF workflow. With Connex, the JDF for each job can be generated in a few mouse clicks. Connex can be used as a fully functional, stand-alone solution or as an interface to an MIS.
The SigmaLine: from the roll to the completed book in one operation
So that the benefits of digital book production are fully utilized, the sub-processes have to be integrated with one another. The SigmaControl line control system is the core of the SigmaLine. It controls and monitors all the sub-processes that are relevant to production:
Digital printing
At the beginning of the production process, the digital press prints each product in one pass – from the first to the last page. Printing systems from different partners can be used. They are completely integrated in the SigmaControl line control system. This makes the digital press a part of the continuous JDF workflow.
Cutting/folding
The printed web is then cut, perforated and folded in the SigmaFolder signature folder. The high-performance cutting cylinder automatically adjusts to the required cutting length and its dynamic control system ensures that each signature is cut at precisely the right place.
The web is folded longitudinal over a former before the cutting operation. After cutting, chop folders make a cross fold and then another length fold. The SigmaFolder is fully automated. In order to make the best use of the web width, it is possible to configure the machine for 8, 12 or 16 page signatures.
Gathering
The SigmaCollator gathering machine collects the folded signatures into book blocks. So that the signature flow can continue to be processed without interruption, the gathering machine stacks the signatures in two gathering trays alternately to form the book blocks. The SigmaCollator automatically resets the size and thickness during production when the job is changed.
Perfect binding
Finally, the SigmaBinder finishes the collated book blocks, binding them into softcover books. It processes different book sizes and thicknesses without interruption, without empty cycles and at full production speed. Thanks to the full automation, it is possible to produce very small runs – just one copy, in extreme cases.
In the measuring station upstream of the perfect binder, the data (size and thickness) for each book is recorded during the production run and used with precise timing to automatically adjust the perfect binder.
After binding, the compact SigmaTower cooling tower ensures that the books are cooled and dried as necessary. As the lift is synchronized, the line control system can trace the products copy by copy through the cooling tower as far as the downstream three knife trimmer.
Trimming
The SigmaTrimmer three-knife trimmer consists of three independent knife elements. In the innovative rotation principle, first the foot, then the front and then the head is trimmed. The size and thickness can be readjusted on the fly from book to book – with no empty cycles. The size data is transferred from the line control system to the SigmaTrimmer with precise timing.
After the trimming operation in the SigmaTrimmer, the finished products can be removed. Muller Martini supplies various options for this purpose, ranging from a simple roller table delivery through the automatic book stacker to complex removal, wrapping and packaging systems.
The SigmaControl line control system integrates prepress, digital print and finishing into a complete system. It can interact continuously with the integrated digital press and issue all the control information and commands. This means that new jobs can be prepared whilst the line is in operation. The SigmaLine production list is fed permanently with new jobs. The Connex workflow system can arrange the jobs in the SigmaControl production list in order to ensure that efficient use is made of the line.
It is this consistent integration of all the sub-processes into a unique total solution and the fully automated single-operation production sequence, from PDF to the finished book, which makes it possible to produce small runs extremely quickly and economically.
A concentration of technical expertise
As digital printing systems become more powerful, they are opening up increasing numbers of new market areas. Whereas digital printing until recently was mainly used in transaction and mailing printing, it is now gaining in significance for book production. Muller Martini, as a world leader in print finishing, is familiar with the high demands made of processes in the graphic arts industry. The SigmaLine stands out with its concentration of technical expertise.
The advantages:
– Industrial-strength design for multishift operation
– highest level of automation
– industrial quality of the finished end product
– a total solution from Muller Martini