The solution for automatic packing in telescope type cartons now offered by Duerselen, Moenchengladbach, Germany, closes the gap in modern print finishing. For drupa 2012 two brand new patented systems for this process will be on display.

Packing system VA.02 integrated a completely automated workflow for packing of (brochure) stacks into telescope cartons: up to 700 stacks /h are fed from upstream machines and – if needed – turned fort he packing process. The stacks are aligned in free fall and the bottom part of the carton is drawn over. The half packed stack is turned and the lid is drawn over afterwards. The now ready packed stack / carton can be labelled and delivered for (automated) palletizing. The whole system is adjustable at the push of a button for stack sizes between 210 x 210 mm and 250 x 350 mm. The carton storage holds boxes for approximately 1 h production time. The system processes as well cartons made of chipboard as of micro-corrugated board.

To get the full benefit from the rationalization offered by packing system VA.02 it makes sense to feed it from more than one brochure production line (perfect binders, stitching lines). For this purpose Duerselen presents the packing line at drupa 2012 together with a suspension track system. Packing and palletizing can now be done in a different location than the brochure production itself. This optimizes the use of production space. Automation of the packing process is not limited to one brochure production line. The brochure stacks are lifted up to ceiling height and moved into hanging transport units. With a suspension track system they can now be moved in any direction without space consumption on the floor / the working area.

For smaller runs Duerselen shows a brand new system: turning unit DS.01 which supports manual packing into telescope cartons. The workflow is made easy, quick and structured. Usually the carton bottom is opened on a packing table and then filled from above with several layers of brochures before the lid is drawn over. Filling from above includes high physical stress for the staff: lifting of the heavy stacks and hand injuries from the sharp edges of the cardboard boxes.

Turning device DS.01 allows quick, safe and stress-free packing into telescope cartons with two persons. The brochure stacks are fed onto an air bed table from any upstream machine. The first person aligns the stack and pulls over the bottom part of the carton. The brochures are not lifted but stay on the air bed table. The half packed stack is pushed into turning unit DS.01. The unit clamps carton and stack and turns it by 180 degrees. After that the half packed stack is delivered onto another air bed table where the second person draws the lid part of the carton over. The closed carton filled with brochures can now be palletized (by hand or automatically). For lower output needs turning unit DS.01 can be operated by one person only. Then the half packed stacks are turned and delivered to the same side from which they were fed.

Using turning unit DS.01 in the packing process causes a massive load removal for the staff. Lifting of the brochures is no longer needed. Output can be increased up to 700 stacks / h by the simple and structured workflow without additional manpower. The partial automation still allows visual checks on the brochures. The design of turning device DS.01 is focused on operational safety and ergonomic workflow. The machine can be easily moved with a pallet truck and thus be used at any location in the production area.

With regards to paper drilling Duerselen shows easy to operate solutions for all standard applications and highly productive systems for many special jobs. Except of an economic entry level four-spindle drill all machines are equipped for professional use and can be used for mostly any materials and hole patterns. Multi-spindel drilling machines for wire-comb patterns ("drilling instead of punching") are as well part of the range as efficient four-spindle drilling machines for file hole patterns.

PB.15 is a fully automated high performance drilling system. The machine processes stacks consisting of perfect bound or stitched brochures, loose leafs or folded products at an output up to 1.400 stacks / h. This system can either be fed by hand or linked in-line with other finishing equipment. In its on-demand version drilling system PB.15 has two frre programmable drill heads. That allows job change over at the push of a button – no make-ready time at all. A smaller on-demand solution is model PB.10 DoD: the stacks are inserted manually but job changeover is done at the push of a button.

Drilling of large sheets printed with multiple images – e.g. tags – is another special job for which Duerselen shows a bespoke solution ("drilling before cutting").On model PB.05 the large sheets are processed like on a guillotine cutter with drill heads (up to 22) instead of a knife. They are moved forward in programmed steps and drilled in rows – an enormous rationalization compared to drilling in small strips.

The two new packing solutions and the well approved paper drilling machines show the modern engineering concept of Duerselen: efficient solutions for print finishing.

For any further information please visit our website at www.duerselen.de or visit us in hall 6, stand A44.