Finishing Technology Outlook – 2022

There’s something pretty fascinating going on in the finishing category. For the (many) years that I’ve been following advancements in the industry, this is the year that I’ve seen finishing automation really hit its stride in a new way.

To clarify, there have been incredible finishing technologies that have launched over the past several years, but what I want you to take note of in 2022 is the truly buttoned-up “systems” that are coming out. Systems that enhance already automated folders, perfect binders, cutters and the like, combining several finishing steps and drastically reducing touchpoints, improving quality and stabilizing costs.

We’re also seeing impressive solutions for the heaviest-touch tasks that can no longer be solved (economically) by teams of low-skilled workers—these have always been some of the toughest to automate, and therefore the last to show up at the automation “party,” so-to-speak.

And it’s not just on the mechanical side of the process—there are big advancements on the software side as well—for instance, fully automated machines that are further enhancing their production throughput with the use of Artificial Intelligence (AI). We’re talking next-level problem solving, automation and optimization of an entire process, rather than a string of automated steps or functions.

Having programmable finishing equipment on the shop floor is one thing, but the ability to automate an entire finishing workflow is the next frontier for many printers.

“Automation has taken on a secondary meaning for most customers we talk to that still have traditional finishing departments,” said Lance Martin, VP marketing for MBO America. “Most required multiple steps and handling to get to the final product. Perhaps cut, then score, then fold, then a QC check using three to four separate pieces of equipment. The time it takes to go through this path and the number of people it requires is daunting. This model will not make sense to the print shops of the future, and the transition has already begun.”

It seems Chris Raney, VP of postpress for Heidelberg, would agree.

“The lack of labor, especially in production plants, put pressure on the production volumes and forced companies to look at higher output machinery and increased automation to find ways to produce the same or more with fewer people," he said. "This brought the need to automate processes to companies that would never have considered it previously. In relation to labor, inflation has pushed up wages, which also directly supports investment in automation as a way to stabilize costs.”

So, what’s new in 2022?

In short, there’s a lot to explore in the finishing category this year, so let’s jump in head-first with the highlights.

Fold and Stack

One of the newest examples of end-to-end finishing automation is the MBO Autonomous Production System—a modular system made up of the K8RS Pallet-fed Folder, VT50 Inspection Unit, Autopilot Controls, KT90 Turn Unit, A80 Stacker and CoBo-Stack Palletizer.

Once a pallet of printed paper is loaded into the Palletized Folder Feeder, the system takes over. It feeds the paper, checks for marks on the sheets for the beginning and end of a job, folds the signature, scans the dimensions of the final folded product for accuracy, rejects the poor ones, then stacks and palletizes the good ones. The entire process can run stress-free at full speeds of up to 30,000 sph with a single operator.

Rollem’s Insignia Die-Cutter was designed to allow print service providers the versatility to pivot production demands as needed from short-mid runs of folding cartons to kiss-cutting work in a very easy changeover process. While cartons require dual magnetic cylinders for die-cutting, creasing, perforating and hole punching—the Insignia can run decals, stickers or other kiss-cut products on the same dual mag setup, which is accomplished by using a single die against a blank jacket on the cylinder. Other benefits include 4,000 sph die-cutting speeds and three efficient, end of line off-loading options (a stripping unit, the vertically receding StackMaster, or a removable cassette).

Koenig & Bauer introduced the CutPRO Q 106 SB with Cut2Print optical registration—a newly designed and engineered high-speed flatbed die-cutter that promises superior productivity and greater throughput of folding cartons. The CutPRO Q has a top speed of 9000 sheets per hour and can handle folding carton stock up to 60 point and fluted stock up to 3mm. The CutPRO Q also has a new sheet interleaving device that is completely makeready-free.

To reduce labor and speed-up production in the die-cutting process, much of the focus should be given to the delivery area—and the biggest issue in high-speed die-cutting is the challenge of taking the final product off the machine without needing four people to keep up with the high rate of speed. To directly address this issue, Bograma has built the STA 550 R Stacking Delivery that has the ability to run a six-up product at 8000 sph, all with the oversight of just a single operator.

The Moll FlexCut 760 Digital Rotary Die Cutter produces premium quality knick-less die-cutting, plus kiss-cutting, scoring, slitting and perforating all in one pass for commercial and packaging applications up to 24 pt paperboard. The machine is very useful for CR80 loyalty/gift cards, too. Servo driver pre-registration ensures that the cut follows the slight movement seen in the digital printing process. The system reads a digital print reference mark and adjusts the cut for every print at speeds of up to 7,000 sheets per hour. Without the knicks/ties the machine easily strips the waste away on each and every sheet that comes out, eliminating tedious hand stripping and cleanup.

Trim, Splice

The new Hunkeler DocuTrim will be available in North America later this year. The DocuTrim is a multifunctional sheet processing system that will meet the requirements of the latest generation of printers. It runs inline with sheet-fed production printing systems and also can be run offline. It enables the cutting of various formats and position-independent slit cuts and chip-outs. Thanks to the system’s modular design, a wide range of solutions can be individually added to create the idea solution for your operation.

The Hunkeler RX8 Roll Changer and Splicer is an exciting new product from Hunkeler’s Generation 8 line of solutions for today’s continuous feed inkjet printers. The RX8 allows automated, non-stop roll-to-roll printing and automated splicing at speeds of up to 800 feet per minute. Two unwinding stations and an integrated web buffer allow for continuous paper feeding into the printer or finishing solution during the splicing process. Other benefits include the ability to handle rolls of different diameters or partial rolls, different types of paper rolls (ex: switching between different weights, colors), ergonomic roll loading and more.

Tecnau will be launching BookReady in mid-2022. As the name implies, BookReady will be aimed at book applications. Book blocks are neatly cut, stacked, offset separated and delivered to a belt conveyor ready for the next finishing process. BookReady is based on Tecnau’s established Stack 1010 system, and will be introduced as an inline system for the Canon varioPRINT 6000 TITAN series of monochrome digital presses. It will also be available as an offline system with added feeder to run output from any sheet-fed print platform. Enhancements include significantly reduced footprint and automated job changeovers at full speed without operator intervention.

Book Binding

Three new Horizon Bookbinding Accessories were recently introduced for the BQ-500 four-clamp Perfect Binder—a machine that enables book-of-one production at speeds of up to 800 books/hour. Horizon launched the LBF-500 Book Block Feeder, along with two new accessories for case bound book preparation—the ESF-1000 End Sheet Feeder, and the GF-500 Gauze Feeder. In alignment with this year’s theme of end-to-end automation, the machines can be configured from standalone systems into a fully connected Smart Binding workflow that provides a highly efficient solution to challenges such as improving speed, quality and decreasing the labor and material costs associated with applying end sheets and gauze to case bound books.

The complete portfolio of Muller Martini saddle stitchers has been renewed with the Prinova at 9000 cycles/h and the Primera PRO at 14000 cycles/h. These two new highly automated saddle stitchers cover the need of today's market for seamless production of smaller jobs with reduced changeover times and fewer operators. Features include a newly-developed feeder for the Prinova and a fully-automated trimmer for the Primera PRO which significantly simplifies the operation of the machines.

Also from Muller Martini, the successful Vareo perfect binder has been further improved and is now called Vareo PRO. In an in-line configuration with the end-sheet tipper and the InfiniTrim trimmer, the flexible VareoPRO can produce both softcover books and hardcover book-blocks (with end-sheets and mull station) in a mixed mode during the same production sequence. In the high-performance category, the Publica PRO range of perfect binders has been introduced, offering a range from 12000 to 18000 cycles/h.

Software Technology

Highcon Systems Ltd. and Tilia Labs announced a partnership that will build the unique software capabilities of tilia Phoenix into every Highcon system going forward and offer them to existing customers. The software will automatically place optimized nicks and stripping lines within tilia Phoenix, its flagship planning and imposition application that employs Artificial Intelligence (AI) technology that enables optimal imposition and dynamic jobs ganging. These capabilities will reduce the number of production runs, makereadies and changeovers, allowing Highcon customers to produce more jobs per shift, and increasing total throughput and revenue for cardboard and corrugated manufacturers.

To reduce makeready time at the guillotine cutter, Polar customers can implement the Polar Compucut system. This software allows the cutting program to be prepared offline in pre-press and then downloaded to the cutter. By implementing this, printers will reduce the makeready time on a cutter down to just a few seconds, dramatically increasing the output.

Packaging

Given the growth in the packaging segment there have been great opportunities for commercial printers to move into the market. The Easymatrix 106C/CS from Heidelberg is a 41-inch flatbed die-cutter with full stripping capability offering commercial printers the opportunity to enjoy much greater output and more automation in a machine that is as great for folding cartons, as it is for commercial products like greeting cards, folders and more. Moving up to peak-performance models, Heidelberg also offers the Promatrix 106-CSB (7,500 sph) and the recently launched Mastermatrix (9,000 sph).

Increased packaging volumes brings the need for more folding and gluing capability. The Diana GO 85 and the Diana Easy 115 folding carton gluers from MK Masterwork offer high productivity, user-friendliness and easy changeovers. When compared to the lighter and much simpler plough folders common in commercial print, packaging customers find that the Diana machines offer greater flexibility, performance and speed.

Trends and Other Finishing Scoop

Rick Salinas, VP marketing, Duplo USA:

“The trend toward B2 paper sizes is continuing to grow as printers strive to be more efficient and reduce costs. Equipment suppliers must meet this need with appropriate devices. Duplo will release no less than three devices in 2022 to meet this trend—one of which is a B2 spot UV coater with inline foiling.”

“Supply chain has had a large effect on all aspects of our business. It has made inventory control very important. Having a good understanding of trends is critical to put strained resources in area and products where they are needed. You do not want to waste a main board or motor on a machine that will sit in a warehouse for 6–8 months, when it could have been used in a much more popular device. Supply chain will also have an impact on current lines and product development. Products that have aged/sales have slowed may see a more rapid end-of-life to save parts resources for newer models.

April Lytle, regional marketing manager US, Scodix:

“Over the past few years, there’s been an awakening to sustainability being pushed down from brands and specifiers; a new involvement in their print workflow process that was not always stressed. More and more consumers demand that transparency and want the comfort of knowing their products were created with greener processes. Scodix digital enhancement equipment and software focuses on productivity, reduced waste and sustainability, and is the perfect answer to the sustainable messaging brands are asking for from their printers.  

Carl D’Aguiar, technical sales, B&R Moll:

“We find ourselves complimenting the market more and more, especially with changes in the material supply chain, and with PET and plastics becoming more and more difficult to obtain. We are seeing a massive push into cutting 24-point paper with coatings for CR80 loyalty/gift cards.”

Galit Beck, senior marketing manager, Highcon Systems, LTD.:

“With upheavals such as COVID-19, supply chain disruptions, and the demand for shorter lead times, it's no longer just survival of the fittest, it's survival of the quickest. Business that can adapt first to changing demands, will come out on top, and this means investing in solutions that help produce more jobs per shift with maximum efficiency and reduced waste.”

Don Dubuque, director of marketing, Standard Finishing Systems:

“Last year, we predicted that our successful pivot to a live virtual demonstration model would be used long after COVID travel challenges were a thing of the past. Our customers have been able to see specific applications run, often with materials they’ve shipped to us—and get their questions answered without having to travel to our national demo facility. This has proven true, as we continue to do many demonstrations virtually. However, customers have started visiting our demonstration center in-person as well, which is great to see.”

Andy Fetherman, president and CEO, Muller Martini

“In all mature markets, the difficulty to find qualified personnel is a major challenge, and we see growth opportunities in products which are supported by digital transformation and in solutions which significantly reduce the need for personnel. In that respect there will be product launches in digital book production and hardcover production as well as a new solution for digital saddle stitching in the months to come.”