Plate handling fully automated

Within the scope of a € 6.5 Mio. investment, Austrian printing house Johann Sandler has also fully automated its plate making processes. The fact that there are many working steps beyond the classical CtP exposure that can be automated and, therefore, becoming more efficient is broadly recognized within the industry. The example in Marbach, Austria, proves impressively just how much potential for more productivity and quality lies in automated plate handling.

Sandler installed another Heidelberg Speedmaster XL 106 which, thanks to LED dryer and CutStar sheeter, delivers a considerable advantage in terms of productivity. To tap the full potential of this situation, the pre-press department needed a speed-upgrade, too: two brand new Kodak Magnus 800 MCU exposure units ensure a high plate throughput. Managing Director Hannes Sandler knew right from the start of the project, however, that the increased number of short runs could not be handled and brought to the presses the traditional way anymore – without sorting mistakes, plate scratches, and delays. Because of this, he insisted on a consistent automation concept after the CtP devices. Today, complete and pre-sorted plate sets are delivered to the presses on time and without any manual handling. The entire plate making process has become much more streamlined and scratched or missing plates are a thing of the past.

To approach this task, Sandler has opted for NELA’s Plate On Demand concept, which includes a plate logistic system tailored to the Austrian printer’s needs. The system was taken into operation in the summer of 2016. Plate On Demand means that imaged offset plates are sorted according to the production plan and are provided at the right time and to the right location. Next to the NELA SF-Bender, i.e. the bending system that is connected in-line with the two Kodak CtP-devices, the installation includes a fully automated plate sorter with complete control and status display. Coming out of the plate processors, the imaged and exposed printing plates are taken over by NELA transport conveyors through the wall into the press hall, where the plate sorter stands, with its plate trolleys ready to accept the bent plates. As soon as one trolley is full – an overview display above the sorter shows the status of all plate sets that are currently in production – it can easily be detached and moved to the press. This is where the last manual working step happens: taking the plates from the trolley and inserting them into the print units. In the meantime, free trolleys at the sorter already store the plates for the next print jobs.

It is incidentally NELA’s PSC sorting software that has been specifically developed for commercial printing and that is the foundation of Plate On Demand. PSC identifies each plate by an imaged bar code and then assigns it to the right print job or press. According to Alexander Dürregger, head of the pre-press department at Sandler, plate sets for one print job can now easily and safely be directed to their respective presses. The potential for mixed-up plates has been eliminated. In addition to this, Mr. Dürregger sees considerable time savings because only complete plate sets are delivered to the presses and missing plates are no longer found. This is a factor that, says Mr. Dürregger, hadn’t been considered as much previously but now it turned out to be another source of savings. While the new plate handling has led to the expected reduction of resources, the fully automated plate bending helped avoid further manual steps and its negative side effects, such as plate scratching and missing plates. “This has made our production processes faster, more reliable and more harmonious”, resumes Alexander Dürregger.

Mr. Dürregger also lists the criteria that are used at Sandler for plate sorting: cost center ID, order ID, sheet number, color ID, and also the press name.

Considering all savings together, the new plate logistic system will have paid for itself within just a few years. Next to the evident advantage of labor reduction in the pre-press department, the savings in quality assurance are just as large: re-ordered plates, mostly in conjunction with expensive press stand-stills and loss of reputation due to inadequate product quality are – thanks to Plate On Demand – a thing of the past.