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Automation paves the way for savings in energy and raw materials

Thursday, April 22, 2010

Press release from the issuing company

The last few years have seen Muller Martini Book Technology make significant progress in the automation and efficiency of hardcover production systems.  Thanks to intelligent control and drive systems, processes are not only much more precise, but also more energy-efficient.

The new Muller Martini hardcover machines utilize the high-tech control system of an innovative automation system, which includes both hardware and software.  The new compact hardware modules are much smaller and conserve more heat compared to the predecessor series.

Integrated Solution
The drive technology featured in Muller Martini Book Technology hardcover systems is predominantly based on servo motors.  The motors are synchronized and optimized, ensuring that this integrated solution delivers a high level of system efficiency.  The servo motors will only execute processes when a movement is really necessary.  Instead of running empty cycles, the respective station remains idle, thereby conserving all associated components and ensuring that no energy is consumed.  What's more, in contrast to previous technologies, servo technology enables more precise process workflows, thereby avoiding almost all production waste.  The movements of the workstation components run according to the products and are therefore always slightly different, depending on the job.  The optimized activation process results in components to be utilized in different positions, which means they do not wear as quickly in the same areas, so the part actually conserves resources due to its improved durability.

Servo Motors Exchange Energy in the Multiple-axis Module
Multiple-axis modules are used as the control element to link the power source to multiple servo motors.  The operating principle behind the multiple-axis module is that the drive axis brake energy is not converted into heat, but is actually available for another axis to reuse as drive energy.  Any excess energy can then be fed back to the main network.  The servo motors boast an energy efficiency level and efficiency rate to match the latest state-of-the-art technology.  Switching to the new technology has led to a 30% decrease in the energy required by the current bookline generation for positioning processes.

Energy Recovery
The EP 680 joint forming and pressing machine comes with a traditional energy recovery feature; the capacitors temporarily store rotor brake energy, which is then used to speed up the machine again.

Another machine, the Ventura MC thread sewing machine, and other new machine generations have achieved extra savings thanks to new main drives: The three-phase current asynchronous motors meet the latest efficiency classes.  Their efficient bevel gears require up to 40% less energy than conventional drives with worm gears.

Since heating elements are responsible for consuming a large amount of energy, Muller Martini Book Technology has developed compact, well-insulated premelters, which radiate less heat.  To save energy, drying and heating sections are equipped with infrared heaters that only radiate heat when products are being processed and the heater wave length used is also adapted to meet the relevant requirements in terms of energy optimization.  While the wave lengths are adapted to dry water in the gluing sections, the heating section up stream of the Diamant MC uses short-wave infrared heaters, which heats the bookblock right through to the core.

Vacuum Generation by Means of Energy-saving Ejectors
The Ventura MC has been able to cut its air consumption by over 30% in comparison to other areas of production.  This is all thanks to the new type of vacuum generation featuring energy-saving ejectors in the feeder hopper and signature opening station.  The vacuum is generated exactly where it is needed and for as long as it is needed.  This new solution has produced huge energy savings.  Plus, response times at the beginning and end of the suction process are shorter, resulting in greater process reliability.

Waste-free Production Saves Raw Materials
MC technology is highly accurate enabling outstanding quality right from the very first book off the production run.  Cutting down on production waste has a direct impact on reducing the consumption of energy and raw materials.

Automation systems, which Muller Martini has been using in its machines for years, increase the machines' efficiency rate.  The systems use the supplied energy intelligently and efficiently, thus resulting in lower power consumption.  And thanks to the highly accurate processes at the start of production, there is virtually no production waste and savings are also made on raw materials.  This is a vital benefit, especially on small print runs seen more and more with the advance of digital print in book production.




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