Muller Martini

What does the future hold for Mid-Sized Book Manufacturers?

James Kaeli — Tue, 07 May 2013 19:48:17 +0000

The US book business continues to struggle in these challenging economic times. Margins are under increasing pressure, competition is increasingly global, and consequently there is a strong reluctance to reinvest in the business – who knows what will happen over the coming year? While these concerns are certainly justified, the decision to put off investments may not be. Looking at our industry as a whole, there is a significant trend which has been developing over the past few decades– the biggest firms continue to grow and acquire smaller ones. They enjoy economies of scale in sales, purchasing, and distribution. There are fewer and fewer small printers overall, but they still make up most of the industry in terms of numbers of companies. In just a few years we will experience what has already happened to drugstores, large retail chains, and lumber yards – only a few will survive, but they will grow and thrive because they have a better customer-centric solution than their competition. The mid-sized players are the ones feeling the greatest pressure, and in my view, the most vulnerable to not taking investment action right now. As the overall book market continues to shrink, these firms must find ways to maintain their current customer base while reinventing themselves to offer new products and services to attract others. The strategies that enabled these companies to grow over the past few decades are longer relevant. Taking a page from the success stories in other industries may be a good starting point. What were the critical factors that set them apart from the pack? How are they viewed as “different” by their customers? Answering these questions may be the start of real change. . . . . . let me know if you have a success story you want to share . . . . .

Muller Martini’s digital book manufacturing system showcased at Europe’s Print Forum 2013.

tqosej — Wed, 20 Feb 2013 16:39:22 +0000

At the recent Print Forum industry event held in Germany, GGP Media, Europe’s largest book producer, a division of Arvato/Bertelsmann, endorsed Muller Martini’s scalable digital book manufacturing solutions. Since GGP produces many high-print-run books and brochures, the current trend toward shorter runs presents particular challenges for the large printing plant which employs over 1,000 people. According to Uwe Schulz, GGP’s Production/Technology Manager, 30 percent of their titles now have small print runs of 3,000 copies or fewer. That prompted GGP to enter digital printing with an HP T-400 and, following a thorough evaluation, to opt for a nearline print finishing system from Muller Martini.

For softcover books, GGP’s nearline solution consists of Muller Martini’s SigmaFolder II, a SigmaCollator, an Alegro perfect binder and a Solit Three-Knife Trimmer. Hardcover books, after the book blocks have been glued-off on the Alegro, are produced using an existing Muller BL500 bookline.

GGP elected a nearline solution because, as Schulz explained, “The output of the digital printing press from three shifts can be finished using the perfect binder in one shift.” One of the key reasons why GGP, which now operates seven Muller Martini perfect binders, chose a solution from Muller Martini is the Connex data and process management system. Connex erases the challenges of a digital workflow by simply taking in the PDF file and automatically processing the job in positioning and production planning through to the finished book. “I don’t know of any other supplier that offers such a workflow system,” remarked Schulz.

GGP believes that digital printing supplements—not replaces—offset printing. That viewpoint was reinforced by Volker Leonhardt, Managing Director of Muller Martini Germany, who said, “We firmly believe in the coexistence of digital and offset printing.” According to Leonhardt, cost-effective print finishing is required for both printing methods in light of smaller print runs. In other words, very short setup times are the order of the day. “You should invest in systems that are digital-ready,” Leonhardt told an audience of industry decision-makers at Print Forum. “And, you can use such machines for offset today, with the advantage that they are already configured for digital printing.”

Muller Martini’s Solit Three-Knife Trimmer provides unsurpassed trim quality for the low- to mid-range binding market

tqosej — Tue, 12 Feb 2013 17:04:39 +0000

Performance features, which include a 3-minute make-ready, are based on Muller Martini’s highly successful Orbit Trimmer platform

Binders who want to compete in the small and medium print run market need a perfect binding line that can deliver a high level of production in the shortest time possible, while also producing optimum print quality. Muller Martini’s Solit Three-Knife Trimmer meets both criteria with changeover time of less than three minutes, coupled with outstanding quality.

The Solit features:

Complete automation from the book infeed to the trimming center, including the pressing plates and knife cassettes without the use of tools, helps ensure changeover times of less than three minutes.
Patented SmartPress Technology—proven in production on the high-performance Orbit Three Knife Trimmer—produces a gentle, controlled pressing procedure in which the air between the sheets of paper can fully escape from the product. This eliminates chipping and spine wrinkling and is the optimal pre-condition for the perfect trim.
The Solit’s 4,500 cph and 85mm trim thickness capacity represent the highest cycle speeds and the largest format range in its performance class.
Servo-controlled axis and a robust, single-piece machine frame provide quiet runs, a short footprint and excellent accessibility.

Jody Harrison, Division Manager – Book Technology, observed, “The Solit represents a well-positioned product that answers a lot of questions for the mid-range market since it delivers all the automation, speed, throughput and quality that’s available with Muller’s top-line trimming equipment. It can process a variety of products, and just like the higher-end Orbit, the Solit’s crossover capabilities make it an ideal fit for both digital and offset production environments.”

Gary Hughes Named Director of Global Packaging for Muller Martini

tqosej — Sun, 20 Jan 2013 16:56:50 +0000

Print finishing solutions provider to play a more significant role within the worldwide packaging market

Long recognized for its innovative post-press finishing technology, Muller Martini is now expanding its commitment within the packaging press market. Gary Hughes, formerly President of Muller Martini Canada, has been named Director of Global Packaging. In this newly created position, Mr. Hughes will direct and coordinate Muller Martini’s global strategy within the flexible packaging industry.

Muller initiated its commitment to packaging in 2009 when it acquired patents for the Variable Sleeve Offset Press (VSOP). Within the past five years, Muller has successfully penetrated the packaging marketplace and now has over 100 presses printing labels, flexible packaging, cartons and more. Most recently, Muller unveiled a new generation VSOP which features an impressive list of functionality and operational advancements, including a new ergonomic construction.

“Muller’s continued successes within an intensely competitive packaging landscape have made a global strategy all the more critical,” commented Mr. Hughes. “The world’s most powerful brands are demanding innovative packaging solutions that can continue to evolve and change over time. As a global organization, Muller has the capabilities, technology, and resources that can expand our position—and our partnerships—within the packaging industry. We will continue to support printers with the best packaging innovations available, so that they in turn can offer their brand customers the best, most proficient solutions, now and in the future.”

Muller Martini has also announced that Werner Naegeli, formerly President of Muller Martini USA, is now President of Muller Martini North America, which includes Muller Martini Canada. This announcement is in keeping with Muller’s ongoing strategy to further strengthen its international sales and service activities through regionalization. In order to enhance and expand services for all of its customers, Muller Martini has established eight global sales and service centers to oversee Muller’s local sales and service locations. Local offices, staffed with local personnel indigenous to each particular region, remain in full force to provide timely support, services and expertise.

Muller Martini’s standalone EP/MC Book Pressing and Joint Forming machine offers affordable upgrade paths for efficient book production

tqosej — Wed, 16 Jan 2013 16:53:57 +0000

The machine’s innovative Smart Press technology also delivers exceptional quality and very low operating cost

What truly distinguishes the EP/MC from competing systems is its innovative Smart Press motion control (MC) technology. Typically, some book blocks have a tendency toward wavy stock which in turn creates an increased risk of wrinkled end sheets. Smart Press significantly reduces the likelihood of this outcome since it provides a single action, continuous pressing force across the entire face of the book. The initial pressing action can be precisely controlled to relieve the surface tension between the end sheets and the book block prior to applying full pressure. This ensures that the pressing is firm and accurate, and that books are cased-in without bubbles or wrinkles.

The EP/MC Book Pressing and Joint Forming machine can also replace its aging counterparts on both legacy Muller Martini as well as Kolbus casing-in lines to reduce maintenance and utility costs and improve setup time and book quality. It can also be used to automate manual work cells in short run conventional and/or digital book facilities, reducing operating costs and crewing, while simultaneously stabilizing quality and raising throughput.

The highly automated EP/MC Pressing System produces the same quality book as Muller Martini’s popular Diamant MC bookline and can accommodate both flat back and rounded spine formats without the need for any exchange parts during changeovers.

The EP/MC upgrade also features a maintenance-friendly design, and its compact footprint provides excellent operator access and visibility into the interior of the machine. The machine has a total of five independent servo drives which eliminate mechanical linkages so more accurate and repeatable setups and quicker changeovers are the norm. What’s more, with only one hydraulic cylinder action per book, there is a significant reduction in oil leaks. The machine’s lower utility requirements for power and compressed air also cut operating expenses.

Jim Kaeli, Business Development – Hardcover Systems at Muller Martini, had this to say about one of the EP’s most underrated features—its affordability and scalability:

“The economic landscape continues to be paved with cautious optimism. That said, the standalone EP/MC represents an excellent value because it’s a protected investment. It can be added to existing legacy lines or it can replace existing manual work cells. And, as a company’s business grows, they can quickly and easily expand into a full Diamant MC casing-in system.”

Muller’s Diamant MC bookline with Motion Control technology has built a solid base of satisfied customers. It is now at work in over 23 countries, with 38 installations within the United States alone. The machine supports a wide range of applications, including yearbooks, juvenile products and digital photo books.

New White Paper from Muller Martini reports on a promising revenue booster for newspapers and advertisers

tqosej — Sat, 12 Jan 2013 16:36:06 +0000

An Update to “Success in Motion” details the expanding importance of distribution

Muller Martini has just released an Update to its highly successful “Success in Motion” White Paper which discussed how newspapers, manufacturing partners and advertisers have initiated business-building strategies that are moving the industry forward.

Distribution, a strategy that goes back to the very beginnings of the newspaper business, is now the focus of an all-new White Paper Update. Author Gary Owen, Muller’s Sales Director, Mailroom Systems, commented, “When choosing a topic for the Update, it became apparent the significant importance that distribution continues to have and the ways distribution continues to redefine itself. Newspapers are leveraging their delivery route ‘footprints’ in order to provide advertisers access to consumers in ways that go beyond the printed paper.”

The report looks at the industry’s current distribution models as well as new mapping and digital technologies which are making it possible to hyper-select consumers based on buying preferences. In addition, the continuing role of the United States Postal Service in providing timely and cost-effective distribution services is also discussed.

Three of Muller Martini’s strategic partners—Forum Communications, The Peoria Journal Star and Tribune Company—assisted in this Update through case studies that further illustrate the evolving role of distribution within their organizations. In addition, the case studies detail mailroom machines and technologies that are helping to facilitate the growing potential of distribution, while driving productivity.

“Success in Motion,” which now includes the “Expanding Role of Distribution” Update, is available as a free download on the Muller Martini website. Those interested in obtaining a copy should visit the Channel MM media hub page at http://blogmmus.com and click on the White Paper icon.

ABOUT MULLER MARTINI

Muller Martini (www.mullermartiniusa.com) is the world’s largest producer of print finishing solutions for commercial and book printers, trade binderies, newspapers and digital book manufacturers. They are also the world’s leading manufacturer of variable size web offset presses. Muller’s innovative workflow solutions optimize processing efficiencies, while helping to build new revenue streams. With U.S. headquarters in Hauppauge, New York, Muller’s sales and support team provides training and responsive service to printers and binderies nationwide.

Muller Martini’s exceptionally versatile Variable Size Offset Printing Press (VSOP) is well-received at this year’s Pack Expo

Joe Anzalone — Wed, 12 Dec 2012 15:42:12 +0000

Despite Hurricane Sandy, this was the largest Pack Expo International since 2006.

Packaging professionals gathered in Chicago October 28-31 to attend Pack Expo, the largest packaging and processing trade event in the world. Amid an epic Northeast hurricane, the show still attracted 45,000 attendees, many from international locations. And, for the first time, the event maxed out McCormick Place, covering more than 1.1 million net square feet, an increase of over 6 percent from 2010.

Muller Martini’s Press Division was well-represented, showing off its new generation VSOP web offset printing press. The VSOP prints labels, flexible packaging and folding carton products and features an impressive list of functionality and operational advancements, including:

New ergonomic construction allowing for easier machine access for sleeve changes and daily operation
Innovative electronic control technology utilizing fewer components for greater machine reliability
Efficient external roller setting feature reduces the initial and operational roller setting time by half
Optimized ink train design delivers consistently reproducible ink settings
Modular design philosophy enables flexible machine configurations for a wide range of hybrid packaging printing applications

What’s more, thick substrates which are often used in carton printing can be processed using the VSOP.

Muller’s booth featured a pneumatically powered 33 1/3” wide VSOP print tower which showcased the press’s automated interchangeable sleeve. The VSOP was equipped with a see-through door so that people could observe its changeover technology while the press was actually running. The demonstration showed how easy and fast it is to change the sleeves in order to seamlessly accommodate new printing jobs of variable lengths.

“In addition to our prominent presence in the post-finishing market, Muller Martini is also committed to serving the packaging needs of printers,” commented Carrington Herbert, Muller Martini’s Vice President of Sales. “At this year’s Pack Expo, it was extremely satisfying to see many of our clients exhibiting their VSOP packaging capabilities.” Mr. Herbert added, “The VSOP is a groundbreaking technology which opens up new revenue opportunities for printers around the globe. Just taking into account the size of this year’s Pack Expo, it’s apparent that packaging is an extraordinarily robust market which will continue to grow and evolve. And we’re excited to be a part of it.”

The Acoro A5 and Diamant MC 35 Digital Make a Perfect Digital-Ready Team

Joe Anzalone — Tue, 11 Dec 2012 21:57:58 +0000

CDS equips its state-of-the-art digital center with 18 digital printing presses and two highly automated digital-ready finishing systems from Muller Martini.

For Steven A. Brown, President of CDS—a company of Consolidated Graphics—there is no doubt: “Digital printing is the future. Personalization and customization allow educators, publishers and businesses to target specific customers with print products designed specifically for their needs.”

CDS, founded in 1906, was the first newspaper publisher in Medford, Oregon. Their offset facility is supported by a comprehensive bindery which includes two Starbinder perfect binders and several Muller Martini saddle stitchers. In recent years, CDS has invested significantly in digital systems for their expanding digital facility, also located in Medford.

Various products are printed on 18 digital printing presses: 12 HP Indigo 7000s and 7500s; three Kodak Nexpresses; and three Xeikon 5000/6000s. Commented Brown, “We specialize in simple-to-complex printing solutions for a range of customers in many different industries including education, technology, finance, healthcare and photo books. We combine digital and analog technologies and provide support to our customers throughout the entire production chain, from pre-press to delivery.”

The Acoro A5 Is Digital-Ready…

For print finishing, CDS relies on systems that are digital-ready. The most recent investment is an Acoro A5 perfect binding line from Muller Martini, commissioned in the fall of 2011. It features a manual feed station and a Merit S three-knife trimmer. “We’ve used Muller Martini systems for decades,” said Brown. “They are reliable, functional and flexible, with a service team that responds quickly when needed.”

The Acoro A5 is used for making book blocks for softcover and hardcover products with one-off print runs, such as photo books. It also supports personalized magazines, catalogs, manuals and textbooks. The Acoro binding solution accommodates a thickness variance of 1.5 mm, ideal for one-off production. CDS employs a barcode system throughout the entire process chain, ensuring that each product is matched to the correct case, dust jacket and book block.

…As Is the Diamant MC 35 Digital

Muller’s Diamant MC 35 Digital bookline was put into operation in the fall of 2010. The Diamant line produces books ranging in sizes from 2 mm thin to large format, including photo books, manuals and catalogs. Integral, full-flap or plastic covers are easily accommodated.

The Diamant MC 35 Digital also allows a thickness variance of 1.5 mm, once again reducing downtime for changeovers. When changeovers are needed, the Diamant servo technology allows the line to continue to run. The Diamant is also equipped with a book block/case verification system so that the correct case is matched to the book block. “With ultra-short runs, only barcodes can effectively ensure that the right cover and content are matched,” emphasized Brown.

As with the Acoro A5, CDS considered alternatives to the bookline. According to Brown, “What tipped the scales in favor of Muller Martini was that they met all of our quality and product requirements, something the competition was unable to do.”

It is precisely in the production of digitally printed hardcover books that the Diamant MC Digital offers the highest book quality and efficiency. The Diamant MC Digital, a version of the tried and tested Diamant MC, can be changed over sequentially and is designed particularly for one-off book production, making it ideal for photo books.

“The Diamant is an excellent example of how Muller Martini found a way to combine modern technology with a proven production system,” says Brown. “In my opinion, it is the best bookline available to support our customer requirements.”

A global presence

At its Medford digital center, CDS can complete 18,000 job orders every day. Most orders for ultra-short runs are placed online; however, no orders are processed directly by CDS. “We work exclusively with other companies on a B2B basis, providing the platform, but never directly engaging the end customer,” emphasized Brown.

Every now and then, there is a conventional print job with larger print runs. “It is not true that offset only helps digital printing—often it is the other way around,” said Brown with a grin.

Under the company motto, “Global Printing Services, Local Support,” CDS, with 350 employees, is also active in Europe, Asia and South America, with production facilities in Prague, Czech Republic; London, England; Gero, Japan; and Sao Palo, Brazil.

Muller Martini’s SigmaTrimming Center shows off its “best-selling” potential at this year’s Graph Expo

Joe Anzalone — Thu, 01 Nov 2012 16:00:24 +0000

Hundreds of graphic arts professionals were able to “take the controls” and trim their own best seller.

Attendees looking for ways to increase productivity—as well as select some leisure-time reading—were anxious to visit the Muller Martini booth during Graph Expo. There, they participated in an interactive demonstration of the fully automated SigmaTrimming Center, taking the controls to trim a best-selling title of their choosing. With more than 500 best sellers given away, Muller’s “trim your own best seller” promotion proved to be both a powerful and highly popular demonstration of just how easy and fast digital book manufacturing can be.

The SigmaTrimming Center is designed for commercial-quality finishing of both offset- and digitally produced books in a one-off, short or large-run workflow. At the Muller booth, visitors also experienced a variety of the SigmaTrimming Center’s capabilities, including:

Industry-first zero makeready delivers true 1,000 fully variable books per hour production
Infinite trim variability within the machine specifications easily accommodates non-standard trim sizes
Groundbreaking barcode intelligence ensures real-time error-free data input and machine setup, minimizing production delays
A fixed-position knife station design with limited moving parts helps eliminate wear and provides high-end commercial trim quality

For facilities using multiple inline trimmers, nearline trimmers or flatbed cutters to trim books, the SigmaTrimming Center is a particularly advantageous solution since it consolidates the entire process—without any additional production planning and with considerable labor savings. It is a remarkably cost-effective solution for the efficient production of high volume, one-off or ultra-short-run perfect bound books, whether they’re produced digitally or offset. And, it can be integrated with Muller’s award-winning Scalable SigmaLine technology for a complete digital book manufacturing system, one that can grow as business grows.

Muller Martini’s theme at this year’s Graph Expo was “New or Renewed: Engineered for Greater Productivity.” Equipment demonstrations showed printers and finishers how they can remain competitive and relevant through investments in either new and innovative print and finishing equipment, or in upgrades and other enhancements that can increase throughput in existing machines.

Muller Martini’s “New or Renewed” product offerings are a huge draw at this year’s Graph Expo

Joe Anzalone — Thu, 01 Nov 2012 15:00:17 +0000

Hundreds of Graphic Arts professionals experience the productivity power of the SigmaTrimming Center and ^MMUpToDate.

Muller Martini offered its customers “something for everyone” at this year’s Graph Expo. The “New or Renewed: Engineered for Greater Productivity” theme encompassed Muller’s new digital book manufacturing technology, as well as many powerful machine upgrades and enhancements that can make legacy equipment perform like new.

Booth visitors actively took part in demonstrations which showed off the ease and speed of Muller’s SigmaTrimming Center, the industry’s first zero makeready trimmer which produces 1,000 fully variable books per hour. The machine’s barcode technology enables real-time error-free data input and machine setup. Attendees had the opportunity to operate the SigmaTrimming Center themselves, trimming and binding a best-selling title of their choice. And, Muller’s staff of engineers and product and service specialists was pleased with the response to the “bind your own book” show promotion. Within minutes of the show’s opening, more than 70 people were at the booth ready to “take the controls” of the trimmer.

Muller’s presentation of its ^MMUpToDate productivity improvement program was just as popular. A legacy 335 stitcher was robustly re-engineered with a variety of enhancements, allowing it to complete toe-to-toe with an all-new machine. ^MMUpToDate includes a host of options and upgrades that can empower legacy equipment with new technologies that enhance performance and increase throughput. More than 150 booth visitors received an on-the-spot ^MMUpToDate Productivity Improvement Report that detailed all available upgrades for their specific machines. Moreover, many companies booked an ^MMInspect service, whereby Muller’s factory-trained staff evaluates their entire machine.

“The crowd’s enthusiasm and receptivity to Muller Martini’s product and service offerings was very positive,” commented Werner Naegeli, CEO and President. “Our industry continues to face some challenging days ahead. However, we’ve engineered ways for printers and binderies to maintain their competitiveness and increase productivity utilizing both new and legacy machines. So whether that’s through a capital investment in an all-new digital book manufacturing solution, or in highly affordable upgrades that can reinvigorate an older machine, Muller Martini is positioned to offer the types of productivity enhancements every one of our clients can take advantage of.”

Also commanding the crowd’s attention was Muller’s EasyDrum featuring PerformancePlus Stitching Wire. Normally hidden behind a stitcher, Muller placed an additional EasyDrum in front of the 335 stitcher so visitors could get an up-close look at exactly how it performs. Containing 650 pounds of wire, the EasyDrum reduces the total cost of stitching by over 35 percent. And, because of its high capacity, it dramatically lessens downtime caused by new spool changes. The EasyDrum, combined with PerformancePlus Stitching Wire and the all-new PerformancePlus Two Heads, represents a complete, highly cost-effective wire system solution for high-speed stitching.