As the most powerful saddle stitcher in the mid-range segment, the Primera 160 saddle stitcher from Muller Martini is an extremely versatile piece of equipment and, thanks to comprehensive process monitoring, it provides a high level of production reliability.

The high net output of 16,000 cycles per hour in all run lengths and wide range of sizes makes the Primera 160 a powerful all-round machine. Thanks to its ergonomic design and modern control concept, the Primera is extremely user-friendly and is quick to set up. Machine operators particularly appreciate the clearly laid-out setup wizard, which considerably reduces the setup time to a mere seven-step process.

Covering Two Automation Classes
"Today's customers face individual challenges in terms of run sizes, size range and job structure," explains Felix Stirnimann, Head of Marketing at Muller Martini Print Finishing Systems AG. And, in turn this requires customer-specific system solutions, which is why Muller Martini offers the Primera 160 with two different levels of automation."

The feeder, gathering chain, stitching machine and three-knife trimmer are all synchronized automatically on the Primera C160 and the optimum engaging positions can be calculated using the sizes submitted. The units are then automatically engaged in the correct duty cycle.

The Primera E160 features the fully automated AMRYS size setup solution (Automatic Make Ready System). The feeder, stitching machine, three-knife trimmer and stacker are quickly and automatically set to the required size and synchronized, which means this saddle stitcher is set up and ready to produce the new job in the shortest possible time.

Single Gathering Chain Ensures High Productivity
To ensure it can deliver reliable and efficient production at speeds of up to 16,000 cycles an hour, the Primera 160 features a single gathering chain. The close fitting feed for the signature enables the signature stability to be improved when being conveyed. In addition, the Magic Wheel in the feeder ensures that the signature is transported longer and guided and securely placed on the chain during feed mode. The cutting process for the sturdy 0408 three-knife trimmer has been optimized to boost the productivity one step further: The new servo-controlled pressing device releases the product immediately after the cutting action for downstream processing.

Customized Product Make-up
Besides its high productivity, the Primera 160 also sets itself apart through its flexible production capabilities: products in the A7 to A3 size range can be produced in a range of customized variations, even in two-up or three-up production.  "In this performance range, we have found that our customers' orders are becomingly increasingly complex and the product make-up ever more extensive. Therefore, feeder reconfiguration on the new Primera 160 is even quicker and simpler to accommodate individual jobs," says Mr. Stirnimann.

A versatile conversion trolley means that folder feeders, signature feeders and merchandise tippers are incredibly easy to transfer so the machine can be prepared for the new job. The new 0382 mobile merchandise tipper increases the number of product make-up variations; it can be quickly inserted into any position without much extra work to produce cards, merchandise samples and CDs

Production Reliability is the Key
A comprehensive process monitoring system is vital when it comes to achieving high net outputs, which is why the Primera 160 offers extensive quality checks to ensure impeccable stitching quality, complete products and considerably less production waste. The new Smart Stitch Control staple control not only checks whether staples are present, but also that they are the correct shape.

Thanks to the Connex workflow system from Muller Martini, the Primera 160 is quick to integrate into the digital workflow, and the new Connex information system logs the current production data and displays it on a desktop or large screen.