The Need for Digital Finishing

1. The Need for Digital Finishing Paul Williams Morgana Systems Ltd

2. Who Are We? • Privately Owned UK Company • Founded in 1977 • Based in Milton Keynes • 80 km North of London, UK • Originally formed as a Sales and Service company • Started manufacturing and exporting in 1984 • First products UFO Folder and FSN Numbering Machine • Still in range today • circa 100 employees, Sales, Service, R&D and Production

3. Manufacturing Facility

4. What Do We Do? • Design and build finishing machines • Primarily for the Digital Printing Segment • Distribute products for other manufacturers • If they offer exclusivity and suit the digital market • Sell and service direct in the UK • Through distributors and dealers in other markets. • Work with most of the Digital Engine manufacturers and Suppliers • Identify niche markets • React quickly, solve printers’ problems

5. What Problems? • Creasing versus Scoring

6. Creasing versus Scoring • Litho ink soaks into the stock • Scoring wheel will “cut” into the surface but when folded the colour will be seen. Job looks OK! • Digital print fuses to the surface • Scoring wheel will “cut” through the toner and when folded white stock will be seen. Job looks terrible!

7. How do we Solve Problems? • New Technology • Matrix Crease and Rule • 6 tonnes of pressure applied • Fibres are compressed and not cut • Crease even across the sheet • Can fold in either direction • Lifetime Warranty on Matrix

8. Why Finishing? • Finishing has always been the “Cinderella” of the Printing Industry! • Investment in Pre-Press (DTP) • Then in CtP, then in Automatic Presses • Now in Digital Print Engines • Offering excellent quality • Getting faster • Becoming less expensive

9. Why Invest in Finishing? • Finally it is the turn for investment in Finishing! • The print market has vast over capacity • Pricing is under extreme pressure • Print quality is becoming generic • Customers expect quality in everything • Service levels are “expected” and are less of a benefit • A 2 day turn-around is no longer good enough

10. Why Invest in Finishing? • The question being asked is:- “If I can’t differentiate through quality and service and if prices are in decline how do I make money?” • The answer is:- “By becoming a total solution provider for your customer”

11. What is a Total Solution? • From “data to document” • Customers don’t want a stack of printed sheets • They want finished (completed) documents • Booklets, brochures, bound reports, manuals, leaflets etc

12. What is a Total Solution? • The more you do for your customer the less they will worry about the cost of it! • Data management, design, creation, printing, finishing, mailing • Total Fulfilment • Remove their “headaches” • Offer a “Data to Document” service

13. Why Digital Finishing? • So if we agree that we need to supply finished documents...... • Why can’t I use my conventional finishing equipment? • Set-up times • Cost (purchase price and hourly) • Waste • Paper handling characteristics

14. Why can’t I use what I’ve got? • Disruption! • Would you set up a stitch-liner to produce 30 x 16pp page books? • The waste would be more than the job! • The time would be longer than the print run • What damage may be done to the print?

15. Why can’t I use what I’ve got? • Disruption! • Would you stop the Polar guillotine to cut 250 business cards? • Average run 13 sheets 18 cuts • How long would it take? • What effect on other work?

16. Why can’t I use what I’ve got? • Disruption! • Would you stop the Stahl folder to fold 50 laminated menus? • How long would the set-up be? • What would the waste be? • What damage would be caused to the digital print? • Would the print crack?

17. Can I Use my Existing Equipment? • Yes...but only if you will accept • Long set-up times • High waste as a percentage of the total job • Damaged print due to mechanical handling • Unnecessary cost tying up large equipment for small runs • So really the answer is No!

18. What “Digital Finishing” is Available? • Creasing...(not scoring) • designed to stop cracking • Folders • designed not to mark the printed sheet • Booklet Makers • designed to feed multiple weights of stock • and to crease (cover, centre spread & individual sheets)

19. What “Digital Finishing” is Available • Creaser/Folders • will multiple crease and fold in one pass • Creaser/Folders • one crease and fold for greeting card market • Perfect Binders • using PUR glue...needed to hold digital print • UV Coaters • designed to protect and enhance digital print

20. Online versus Nearline • Online • Operations that produce the same product everyday • Financial – Educational – Governmental • Those who do not require flexibility • The system is only as fast as its slowest component • Nearline • Digital Engines run at optimum speed • Flexibility of production & finishing techniques • Still have production if failure occurs

21. Digital Finishing Products • Wide range available • Many suppliers offer some digital products: • Duplo – KAS – Uchida – Nagel – Graphic Wizard to name but a few. • but only one offers everything you will ever need! • Prices range from approx €500 to €70,000+

22. Table Top Creasers Electric Hand Fed, Computerised Manual

23. Automatic Creasers AutoCreaser Pro 50 AutoCreaser Pro 33

24. Creasers • All use matrix an blade method • All offer the same quality of crease • All will crease in either direction • €500 to €15,000

25. Folders Fully Automatic Set-Up Semi-automatic Set-Up Major DocuFold

26. Folders • For pre-creased stocks • Small footprint • Easy to use • semi-automatic • fully automatic • Pre-set folds

27. Creaser Folders many have tried....few have succeeded DigiFold Pro AutoFold Pro

28. Crease & Fold Technology • No marking of the sheets • “Flying Knife” patented Folding • DynaCrease patented “on the fly” Creasing • Very high speed • DigiFold - 6000 sheets per hour

29. DynaCrease Technology 9 creases on 9 sheets in 9 seconds!

30. Flying Knife Technology Creasing Unit Large non damaging Fold Rollers Flying Knives • Stock is creased • Stock moves into fold unit • First knife pushes stock up to fold on crease 1 • Second knife pushes stock to fold on crease 2 • Folded document arrives on the conveyor

31. Unique Products DigiFold Pro- Computerised high speed creasing and folding machine

32. Booklet Makers DocuMaster. The Complete Finishing System

33. Booklet Maker Technology • Feeds multiple weights from one feeder • perfect for pre-collated sets • cover and inside stock • sonic doubles detection • creases cover and centre spread (or all) • variable data camera system • square-back option • perfect bound look with stitch security

34. UV Coater Protect and Hold Fully Automatic UV Coater

35. UV Coating • Protects the print • Scratching • Postal damage • Enhances the image • Gloss, matt, textured • Easy to use • Can prime as well • Environmentally friendly • Biodegradable • No plastics

36. PUR Binders Easy to Use Environmentally Friendly PUR Binders

37. PUR Binding • 4 x stronger than hot-melt • Will hold digital print • Can bind into gutter or double page spreads • Easy to use • Limited waste • Ideal for short runs

38. Smart Screen Technology

39. Summary • Is Digital Finishing Different? • Yes, as different as an iGen is from a GTO • Do I need specialist products? • Yes, if you want to be profitable and productive and offer a “total solution” • Can you recommend who can help me? • Yes, Morgana can!

40. Thank you very much again for inviting me and thanks for listening!