manroland web systems offers a wide product range for service upgrade solutions that help customers reducing costs and improving quality. As the only press manufacturer in the market, manroland web systems develops in-house ClosedLoop systems that enable a fully integrated operation with user confidence.

Reducing Waste Rates Due to Highly Dynamic Cut-off Register Control
High speed delivery at short lead times is just one trend of modern commercial printing. Smaller runs, aligned with special target groups, additionally have to meet high quality demands. Thus, besides short makeready times, publishing houses more and more require higher quality standards for color and cut-off register – both, for hardcover and for the paperback market. Furthermore, this also means reduced waste rates for the printer, what helps achieving an ideal cost-per-copy for the production.

InlineCutoff Control dynamic (ICCd) for LITHOMAN presslines in Kulmbach
Baumann Druck in Kulmbach faced these demands and decided to invest in ICCd. It has been installed at both LITHOMAN presslines and is running since beginning of May 2015. The installation in Kulmbach is the first ICCd that has been installed at a LITHOMAN short grain press.

Investment Pays out in Just one Year 
“The highest benefits are the reduced waste rates. Due to cost savings, the investment has paid back in just one year”, Marco Piskol, Director Print at Baumann Druck states. 

InlineCutoff Control dynamic is the fastest cut-off register control that is available at the market. This is enabled by an additional camera that measures and controls the web directly in front of the folding knife. The high dynamic of the folder drive systems can react to every measurement and can be re-adjusted for ensuring an accurate cut-off.

According to the system configuration, the customer is able to save more than 50% of cut-off waste at reel changes or single blanket washing. Furthermore a significantly smoother cut with fewer tolerances can be achieved at every production start and run. 
 
Due to this, the selling of the products after interferences like start-up, blanket washing or reel change can be compensated early than with an conventional control with mechanical compensators for cutting positions.  

Baumann Druck – Long-term Successful Cooperation
An 8-page OCTOMAN from 1999 has been the beginning for a long-term partnership with manroland web systems. Since then, Bauman Druck has ordered a LITHOMAN III 40-page press in 2009 and another strongly efficient LITHOMAN 64-page press in 2011. 

The circulation is between 10,000 and 19 million copies per run. Amongst other things, the products are printed climate friendly due to a modern energy management. Since 2012, the company is certified with ISO 50001. 

There are more than 160 employees working at the printing site in Kulmbach. There they produce inline products with high circulations every day: advertising inserts, brochures, catalogues and magazines.