Customer Workshop Folder Prague January 2018

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Asher Burns
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1 Customer Workshop Folder Prague January 2018 Matthias Schöffler

2 Situation today (very often) Press good technical standards and production capacity in Press department Bindery most folders are used, less capacity per folder, long set up times, no skilled Operators, Helper from Leasing company are not interested, one operator set up all machines

3 Heidelberg Strategy push to stop in Postpress Driving Productivity & Uptime Automatization for reducing set up times Folder in shingling mode for high volume production Helpful ideas at deliveries experience in handling with high productive folders

4 Price Positioning Every customer finds his suitable machine with Heidelberg, adapted to his requirements TH/KH 82-P TX 96 NEW at drupa: Stahlfolder TH/KH 82-P TH/KH BH/CH Ti With 16-pages A g/m² (average value) Highest Flexibility in Application and equipment Industrial Signature Production > Performance Class sheets/h All folders from format 56 till 96 in manual and automated version available Heidelberger Druckmaschinen AG

5 Faster set up time by automation TH56 Folding time Test Comparison of automation against manual machine. All jobs ran on 115 gsm stock, white paper folding edge to edge at 120 m / min. All make readies include running a total of 100 good copies. Heidelberger Druckmaschinen AG

6 Automation in Practices Heidelberger Druckmaschinen AG Set up time min Set up manual more then 10 Touch points Set up time 5-10 min Automated set up

7 Automation in Practices Customer statement Experience from Mr. Company.. Folder. Heidelberger Druckmaschinen AG

Heidelberg Aim is - for the processing of the production of a press, for ex.

8 Treatment of the subjects new folding machines generation Request from our customer is: - one Press, - one Folder, - one Operator of Folding machine development at Heidelberg Aim is - for the processing of the production of a press, for ex. 15,000 sheets / H should one folding machine with one operator be used Video Speedmaster Folder

Innovative Folding The speed specification in m/min does not reveal anything about the productivity of the machine. The Stahl-O-Mat of 1975 had a max.

9 Innovative Folding The speed specification in m/min does not reveal anything about the productivity of the machine. The Stahl-O-Mat of 1975 had a max. operation speed of 150 m/min The speeds were not achieved due to lacking process reliability in production The modern electronics of new constructions allow for an absolutely processreliable run of m/min New machines run with a speed of more than 200 m/min, however, the speed can actually be used only restrictively Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

Wettbewerb Innovative Folding - Borders with the productiveness increase Mechanic operation speed of folding machines can, however, still be increased, but: The restrictions are due to paper and due

10 Wettbewerb Innovative Folding - Borders with the productiveness increase Mechanic operation speed of folding machines can, however, still be increased, but: The restrictions are due to paper and due to the buckle fold principle Impact speeds on stops damage the paper edges High-class surfaces require gentle treatment Speed-up of sheets from the pile in the feeder has been exhausted Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

11 Wettbewerb Innovative Folding - the solution introduced at DRUPA 2016 Transport more sheets with same machine speed by: 1. TX Shingled folding in parallel fold TH 82-P folding unit KH 82-P folding unit standard Mode shingling Mode Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

12 3. Folding station 3. Folding station Feeder/ 1. folding station Feeder/ 1. folding station Innovative Folding continuously shingled Conventional Folding Shingled Folding 3 sheets 3+2 sheets 2. Folding station 2. Folding station Processing of the sheets with sheet gap sheets/hour (16 pages A4) Heidelberger Druckmaschinen AG Stahlfolder Peak Performance Same machine speed 150 m/min Up to 50% more sheets in the same time due to shingled processing of the sheets No special fold types / imposition schemes necessary sheets/hour (16 pages A4)

folding in the second and third folding station (TX-fold unit) Shingled folding in cross

13 Wettbewerb Innovative Folding - the solution Transport more sheets with same machine speed by: Shingling on SRT of second and third station (suction wheel on SRT) Shingled folding in the second and third folding station (TX-fold unit) Shingled folding in cross fold unit Video TH82-P Video KH82-P Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

14 Innovative Folding - Product Launch at Drupa 2016 The bottleneck folding is eliminated with the new Stahlfolder P technology. The Smart Printshop with workflow integration in finishing becomes reality. Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

15 Million* Innovative Folding - Performance Overview Average annual output 2 shifts [sheets] Average performance of today s printing presses TH/KH 82 mit Bogenabstand TH/KH 82 with sheet gap TH/KH 82-P geschupptes TH/KH 82-P Falzen shingled folding TX 96 Queranlage und geschupptes Falzen TX 96 oblong and shingled folding *16-pages A g/m² (average value) Heidelberger Druckmaschinen AG Stahlfolder Peak Performance

16 shingling folds - Training 2016 product portfolio folder figures from customer Performance data and evaluation TH 82-P realistic production data, calculation from Nichts the ändern practice Achim nach Zahlen fragen Production Speed from August 1st. - August 3rd. (anderes Format, Falzart,..) Customer: PDC Paderborn TH 82-P Format Folding scheme pages Paper grammer Paper Speed. m/min Sheet Gap S/h Shingling S/h Increase S/h 63 x x x x x x x x x x 89 S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m S 16 1m+1m+1m Heidelberger Druckmaschinen AG g/m² Bilderdruck Speed matt cm cm g/m² Bilderdruck cm ,5 cm g/m² g/m² g/m² Bilderdruck matt gestrichen Bilderdruck matt gestrichen Bilderdruck matt gestrichen cm ,5 cm ,5 4 cm ,5 cm cm ,5 cm g/m² Profi matt cm cm g/m² Offset cm cm g/m² Offset cm cm g/m² g/m² Bilderdruck matt gestrichen Bilderdruck matt gestrichen cm cm cm cm

17 Strategy of the folding machine development by Heidelberg Aim is achieved - for the processing of the production of a press, for ex. 15,000 sheets / H if a folding machine with an operator is used per shift Video TX 96

Performance of the folder Net-performance = gross-performance nonproductive time Unproductive time by: set up Palette change Stops Machine care etc.

18 Performance of the folder Net-performance = gross-performance nonproductive time Unproductive time by: set up Palette change Stops Machine care etc. Solution attempts in the folder: Automation Standardization Logistics Preventive servicing Heidelberger Druckmaschinen AG Workshop Logistik bei Peak Performance Falzmaschinen 18

19 Abstraction Process Folding unloading folding loading 8 Tons per Shift The fastest machine doesn't run if the operator has too much pressure too hard work 16-pages Stahlfolder TH 82 Stahlfolder TX 96 physical work ~4 t per shift ~8 t per shift Heidelberger Druckmaschinen AG 19

Deliveries palamides alpha hd mark free pile stacker High

of cycles Automatic format recognition to the automatic

pressing free of fold An easy cleaning possibility of the

20 Deliveries palamides alpha hd mark free pile stacker High output capacity 160-mm-high piles for the reduction of number of cycles Automatic format recognition to the automatic setting of the batch shaft Before - and pressing roller for pressing free of fold An easy cleaning possibility of the Pressing rollers by pneumatic opening device Heidelberger Druckmaschinen AG 20

Training 2016 product portfolio folder Deliveries

alpha hd mark free pile delivery Video TX 96

of the machine easy unloading for the for

21 Training 2016 product portfolio folder Deliveries Combination palamides alpha + Transomat palamides alpha hd mark free pile delivery Video TX 96 Transomat Heidelberger Druckmaschinen AG High speed of the machine easy unloading for the for high-capacity production, 15,000 B/h one operator Palamides 500 hd Transomat

Training 2016 product portfolio folder Deliveries Palamides delta 502, 703 Automatic display for Signatures One man operation up to 5 ups are pressed,

22 Training 2016 product portfolio folder Deliveries Palamides delta 502, 703 Automatic display for Signatures One man operation up to 5 ups are pressed, stacked and taped no jogging and rework by Hand Delivery of the Packages in ergonomic working height Video Palamides Delta703 Heidelberger Druckmaschinen AG

23 KH 82, KH 82-P Set up delivery alpha from 32 to16 pages Combi curve Conventional set up time delivery 15 min Benefit: Safe space 1,5 m and set up time 3 min moving delivery on rails Heidelberger Druckmaschinen AG

24 KH 82, KH 82-P Set up delivery alpha from 32 to16 pages Combi curve Conventional set up 15 min Benefit: Safe space 1,5 m and set up time 15min moving delivery on rails Heidelberger Druckmaschinen AG

25 KH 82, KH 82-P Set up delivery alpha from 32 to16 pages Combi curve Conventional set up 15 min Benefit: Safe space 1,5 m and set up time 15min? moving delivery on rails Heidelberger Druckmaschinen AG

Delivery alpha 500 in position for 32 pages

26 Delivery alpha 500 in position for 32 pages using transfer table moving delivery Kombi Curve CC 41 Delivery alpha 500 in position for 16 pages using CombiCurve Link to You Tube for Presentation Push to Stop the Folder Heidelberger Druckmaschinen AG 26

27 Stahlfolder TX 96 Process optimizing change the folding schemata Variable Configuration: 32-sheets 24-sheets 18-sheets delivery: alpha 700 hd Solution with Transomat TX 96 Falzmuster conventional und TX version!!!! Heidelberger Druckmaschinen AG Workshop Logistik bei Peak Performance Falzmaschinen 27

capacity Integrated pressing unit automatic setting of the roller gap Rear mounted slitter

28 Quality of folded sheet in the folding unit integrated pneumatic Pressing unit if the air from the sheets glides and prevents marks more sharp breaks and higher fold quality and batch capacity Integrated pressing unit automatic setting of the roller gap Rear mounted slitter shaft is preserved maximum product thickness up to 3.5 mm non pressed pressed Heidelberger Druckmaschinen AG

New Push to stop in Postpress Running differed

job Stop, Change in the next format Start self reliant

Production time Video Bar- Code Leser Umstellung Start

82-P; TX 96 for palamides alpha 500 hd Complied updates

29 New Push to stop in Postpress Running differed signatures on one pallet Folder realized the end of the job Stop, Change in the next format Start self reliant Benefit: Reducing Touchpoints, Set up`s Waste Production time Video Bar- Code Leser Umstellung Start neuer Job Retrofitting is possible at KH 82-P; KH 82;TH 82-P; TX 96 for palamides alpha 500 hd Complied updates including Software and Cameras Barcode Heidelberger Druckmaschinen AG 29

30 Price-Performance-Positioning Cost per Copy Marge per year YES / NO Cost per shift Cost per year Calculation Cost per machine Heidelberger Druckmaschinen AG Workshop Logistik bei Peak Performance Falzmaschinen 32

96, TH 82-P, KH 82-P Year 2017 69 sold machines Total

31 TX 96, TH 82-P, KH 82-P Drupa result: 33 sold machines TX 96, TH 82-P, KH 82-P Drupa year sold machines TX 96, TH 82-P, KH 82-P Year sold machines Total till today 147 Folder, 20 x TX x TH 82-P 43 x KH 82-P 33

Reference (Heidelberg News April 2017) Experience of users TX 96 Grasl FairPrint Further optimizes processing by consultation Know how and total concept of Heidelberg 200 Millionen Sheets per year

32 Reference (Heidelberg News April 2017) Experience of users TX 96 Grasl FairPrint Further optimizes processing by consultation Know how and total concept of Heidelberg 200 Millionen Sheets per year Since April of this year all new machines in the location are installed in bath Vöslau, and Walter Grasl strikes the first balance: Already by the image of the palette investor PFX on Drupa in 2012 I have recognized the potential of this new technology. The investor uses the same principle like a pressure machine investor. The curves come scaled to Out put is up to 50% higher than with a conventional cross break production. the investor and, in addition, also scaled in the fold work what high throughput provides which is about up to 50 percent higher than eight machines have mastered, now these both machines create. They can easily keep up with the high output by the high automation very well are used for both machines. Furthermore Walter Grasl is inspired by with Both a conventional folders cross process break production. all 16-paces On both steel signatures. folders TX What up to now eight machines 96 we process all 16-sided signatures. What up to now have mastered, now these both machines create. the high run achievement with from 15,000 to 20,000 curves per hour with the slightest machine speed and the very high availability and stable production. of Walter our pressure Grasl machines, is we inspired have been cancelled by the a quicker high order run flow achievement with and it also works on the week-end. Three operators who are supported from to sheets per hour Heidelberger Druckmaschinen AG

Reference Austria 05/17 Bösmüller ordered an KH 82-P and replaced KD 78 and KH 78.

33 Reference Austria 05/17 Bösmüller ordered an KH 82-P and replaced KD 78 and KH % more output and easy handling are the reason for that decision Heidelberger Druckmaschinen AG

34 Reference Austria 05/17 By the automation we could reduce the set up time strongly. Also the storage of the jobs is very helpful for that. The repeat accuracy is high-class Heidelberger Druckmaschinen AG

Reference (Heidelberg News May 2016) experience from user TH 82-P first installation First users of the new folding machine steel folder TH 82-P report about higher productiveness and better

35 Reference (Heidelberg News May 2016) experience from user TH 82-P first installation First users of the new folding machine steel folder TH 82-P report about higher productiveness and better predictability of the processes Kirchner Print media if the highest fold quality achieves with higher achievement. Managers Martin and Alexander Kirchner are very contented with the new steel folders TH 82-P. The folding machine moves the highest quality with higher achievement. Price-achievement relation and saving of time arouses enthusiasm Mr. Kirchner: machine moves the highest quality with higher achievement Heidelberger Druckmaschinen AG

36 Heidelberger Druckmaschinen AG

Equipment. Peak performance. Stahlfolder TX 96.

Equipment. Peak performance. Stahlfolder TX 96. Equipment Peak performance. Stahlfolder TX 96. Maximum performance. Stahlfolder TX 96. Leader in postpress. 10 clear benefits.* Our Stahlfolder TX 96 folding system enables you to achieve the highest output