BRO Digital Print Finishing e8 - hunkeler.ch

Digital Print Finishing

From white paper to finished products

Digital printing is much more than a new way of printing on paper. It’s an on-demand mindset

that disrupts conventional production models. The technology allows effi cient short runs, lower

labor costs and faster turnarounds. And it changes the way service bureaus, commercial printers,

direct mailers and book publishers process paper. Today, print production is a completely fl exible

process that opens up entirely new, unimagined and exciting possibilities.

2

New Generation 8

3 Global distribution network Worldwide service support Modular equipment Security / Content control

Powerful systems for digital paper processing Hunkeler develops and supplies innovative solutions for continuous

feed paper processing througout the digital print process: Modular,

high-performance systems that present the paper to the digital

press and then further process the printed paper through to the end

product. Completely integrated systems are produced in close

partnership with the leading digital press manufacturers. Centrally

controlled, these systems guarantee the highest productivity, fl exibility

and process reliability.

Expert partnership Success in paper processing applications requires knowledge and

experience. We at Hunkeler have been continuously developing and

refi ning this expertise together with our customers since 1922. With

best-in-class engineering, machine components and control units, we

have successfully mastered increasingly complex system integration.

So that everything runs perfectly One reason for the reliability and effi ciency of our systems is the

high level of service support. Around the clock and worldwide.

Individual service modules allow Hunkeler to ensure support that is

exactly tailored to your wishes. Our service hotline with Hunkeler

Remote Assist – plus our spare parts and aftersales service – guarantee

the highest equipment availability. With comprehensive service and

operating documentation to assure professional attention and the

highest possible machine productivity.

Security becomes transparentWith the Hunkeler Control Platform we offer you hardware and

software for quality control and document tracking throughout the

printing process. Scalable design enables customized, user-specifi c

solutions. Thanks to fl awless web inspection and tracking, you will

have good answers to these questions and more in the future. It‘s

always better to be on the safe side, with Hunkeler as your trusted partner.

Hunkeler's versatile dynamic functions such as Dyna-Cut and Dyna-

Scan offer dynamic scanning, cutting and stacking of variable sheet

lengths with automatic changeover during ongoing production.

The result is noticeably higher fl exibility and profi tability by saving

unwanted waste.

4 Hole punching with PP6Paper web dedusting iPEM Quality control with WI8 Roll production with center cut

Roll to Roll Solution The Hunkeler roll to roll solution with different confi gurations for

continuous feed digital presses. High-speed Hunkeler unwinders

and rewinders ensure effi cient, productive downstream processing

in the transactional, direct mail, print-on-demand and packaging

segments, coupled with inserters and other fi nishing systems.

Technical Data* | Roll to Roll

POPP7 Gen8 Gen8-Wide

(UW7) (UW8/RW8) (UW8-W/RW8-W)

Max. roll diameter: 54” (1370 mm) 54” (1370 mm) 54” (1370 mm)

Web width: 6.5” – 30” 6.5” – 22.5” 8” – 30”

Production speed: up to 220 m/min up to 254 m/min up to 305 m/min

up to 720 ft/min up to 833 ft/min up to 1000 ft/min

Paper weights: 40 – 300 gsm 40 – 300 gsm 40 – 350 gsm

Roll weight max.: 800 kg (1760 lb) 900 kg (1984 lb) 1500 kg (3307 lb)

Options: see data sheets

Statements

Invoices

Personalized letters

Transactional

Unwinder

UW8|UW7

Printing System

Rewinder

RW8

Web Inspection

WI8

Unwinder UW8

for Inserters

Printing SystemRewinder RW8-W

Unwinder UW8-W

5

FS6 options

Technical Data* | Roll to Stack Solution Gen8

Max. roll diameter: 54” 1370 mm

Web width: 8” – 22.5” 203 – 571 mm

Production speed: up to 590 ft/min up to 180 m/min

Paper weights: 27 lb offset/book – 110 lb cover 40 – 300 gsm

Stack height: up to 10“ up to 254 mm

Format length: 5“ – 19“ 127 – 482 mm

Variable chip-out: 1/4“ – 2“ 6.3 – 50 mm

Applications: 1up – 4up

Options: Dyna-Cut, Tracking, LS8-30 B2+ stacker

Roll to Stack SolutionHigh-performance Gen8 fi nishing line for the roll-to-stack production

with CS8 cutting module, separation module and LS8 stacking module.

Web widths of up to 22.5 inches will be processed at up to 590 ft/min.

DynaCut function for variable-format production allows cut-off length

changes while running. Gen8 technology is ready for future printing

speeds. Reliable processing of demanding products in full-color on

coated and uncoated standard paper, from light-weight to heavy-

weight grammages. The new Hunkeler Workfl ow Manager provides

user-fi endly and convenient operation of the production line.

Separating

Linear cuttingCross cutting

Sample Workfl ow:

4-up production

Stacking

Stacker LS8

Length- and Cross

Cutter CS8

Printing System

Offset Separator SE

Cutter CS8-I, cross and linear cutting Cutter CS8-II, cross cut, chip-out, linearcut Cutter CS8-II, perforating and cross cutting

Web Buffer

WB8

Fan-Folder

FS6

Web Inspection

WI8

Printing System

Register mark

printing unit

Roll to Fan-Fold Solution The modular Hunkeler roll to fan-fold solution. In 2-up production

individual processing of the two web halves is possible. Combined

use of three different functions is possible in a single DP8 dynamic

processor module (static and dynamic perforation in the vertical and

cross direction, dynamic fi le hole punching, and folding perforation).

Reliable, inline high-speed operation with continuous feed printing

systems in a space saving package with modular options that include

a stack cart system, high capacity stacker, and web inspection.

Technical Data* | Roll to Fan-Fold


Web width: 8” – 20.5” 203 – 520 mm


Paper weights: 16 – 40 lb bond 56 – 160 gsm

Stack height: 39.4“ 1000 mm

Folding perforation: 7“ – 14“ (static) 178 – 355 mm (static)

Folding height: 7“ – 17“ 178 – 432 mm

Options FS6: Shingle Belt Delivery, Stack Cart System, High Capacity Stacker,

Stack Turning

Options PP6: File hole punching, Register Mark printing, different cross

perforation cylinders

HWM

Dynamic Processor

DP8

Unwinder

UW8

Unwinder

UW8

6

Technical Data* | Roll to Stack with DP8 – WM8 – LS8


Web width:* 16” – 20.5” 406 – 520 mm

Production speed:** up to 590 ft/min up to 180 m/min

Paper weights:** 16 – 35 lb bond 60 – 130 gsm (max. 300 gsm)

Stack height up to: 10“ 254 mm


Format length: 5“ – 14“ 127 – 482 mm

File hole punching: 2-, 3-, 4 hole pattern Ø 5.5 – 8 mm

Preferred dies:

* 22.5" / 571 mm with underpath of DP8

** depending on production path

Options: Offset separator SE, Gutter cut, Web Folder WF8

Vertical and cross perforations Full bleed products with CS8-II Quality control with WI8 Web merging with WM8

Roll to Stack Solution with DynamicProcessor and Web Merger The DP8 dynamic processor module is the fi rst solution that combines

perforation in the vertical and cross directions along with punching:

all in one unit. «Dynamic» means the ability to change the perforating,

punching or hole pattern from sheet to sheet.

It is particularly interesting for transpromotional applications or perso-

nalized mailers. Coupons, payment slips and other elements can be

integrated into practically any type of document, even those with forms

that vary with each sheet.

Vouchers

Billings

Policies

Stacker LS8

Web Merger WM8

Web Buffer WB8 Printing System

Dynamic Processor DP8

MergingCross cutting

Center cutting

Merging Process:

Stacking

Offset Separator SE

Transpromo

Length- and Cross

Cutter CS8

Unwinder

UW8

7 Coupon with safety features Pattern-Plugin: easy job setup Perforating and Punching Effi cient 2-up production

Roll to Stack Solution with Dynamic Processor Dynamic perforation and punching combined in a modular concept

of the DP8 dynamic processor module. In 2-up production individual

processing of the two web halves is possible. Combined use of three

different is possible in a single module (dynamic perforation in the

vertical and cross direction, and dynamic fi le hole punching).

Technical Data* | Roll to Stack with DP8


Web width:* 8” – 20.5” 203 – 520 mm

Production speed:** up to 590 ft/min up to 180 m/min

Paper weights:** 11 – 53 lb bond 40 – 200 gsm (max. 300 gsm)

Stack height: 10“ 254 mm

Variable chip-out: 1/4“ – 2“ 6.35 – 50.8 mm

Format length: 5“ – 14“ 127 – 482 mm

File hole punching: 2-, 3-, 4 hole pattern Ø 5.5 – 8 mm

Preferred dies:

* 22.5" / 571 mm with underpath of DP8 and up to 300 gsm paper weight

** depending on production path

Options: Stacker LS8, Web Merger WM8, Web Folder WF8

Web Buffer WB8 Printing System Web Inspection

WI8

Stacker LS8-30

Offset Separator SE

Dynamic Processor

DP8

Performance DP8: Performance DP8: Performance DP8:

s e

Dynamic linearand cross perforation

Dynamic filehole punching

Dynamiccross scoring

Static linear scoring

Length- and Cross

Cutter CS8 Unwinder

UW8

Dynamic Processor DP8 – different configuration possibilities for perforation, punching, scoring and web inspection

WI8 Web Inspection Linear perforation Cross perforation Linear scoring Cross scoring Punching

DP8-I-LDP8-I-L

DP8-II-LDP8-II-L

DP8-I-LLDP8-I-LL

DP8-II-LLDP8-II-LL

DP8-I-P-LDP8-I-P-L

DP8-I-P-LLDP8-I-P-LL

8 Full bleed products with CS8-II Effi cient direct mail production Cross folded direct mailers

Postcards

Selfmailers

Flyers

Cross cuttingFolding

Perforation Folding Process:

Cross foldingDelivering

Technical Data* | Roll to Sheet Solution with Folder WF8


Web width:* 10” – 20.5” 254 – 520 mm


Paper weights:** 16 – 43 lb bond 60 – 160 gsm

Final format length:*** 5.5“ – 62“ 140 – 1575 mm



** folding: 40 –130, perforating: 40 – 200, scoring: 120 – 250, punching: 60 – 120

*** with chip-out

Buckle Folder

Web Folder WF8

Mailing production with web folderProduction of direct mail and a selfmailer from pre-printed roll to folded

end-product at a web speed of up to 180 meters per minute. Mail

pieces are dynamically perforated or scored in both vertical and cross

direction using a DP8 dynamic processor with optional punching.

The paper web is linear fold, registered superimposed in a WF8 web

folder. A CS8 cutting module performs cross-web chip-out before the

sheets are presented in-line to the folding machine. The compact new

WI8 web inspection system employs state-of-the-art CIS technology

(contact image sensor) for quality monitoring while production is in progress.

The new Hunkeler Workfl ow Manager HWM makes job setup, operation

and monitoring of the production line centralized and convenient.

Additional Web merging (WM8)

Dynamic Processor DP8

Direct Mail

Length- and Cross

Cutter CS8

Unwinder

UW8

9Dynamic vertical and cross scoring 300 gsm post cards (up to 4-up) Vertical and cross perforations Folded mailing

Premium quality direct mail production with the latest generation of machinesProducing fi rst-class, four-color printed mailings even on coated paper

from the roll to the cut and folded end-product. Dynamic punching,

vertical and cross scoring or perforation is performed in the DP8

dynamic processor module. The double cross-cutting cylinder in the

CS8 cutting module produces full-bleed documents. The cross-cutting

cylinder in the CS8 can be equipped either with two knives for

variable chip-out, or with one cutting knife and one perforating blade

to produce dynamic folding perforations.

The integrated WI8 Web Inspection System based on the latest high-

speed CIS technology for high-end quality and integrity control.

Technical Data* | Roll to Stack with Folder/Merger


Web width: 10” – 20.5” 254 – 520 mm


Paper weights:* 16 – 43 lb bond 60 – 160 gsm


Format length: 5“ – 14“ 127 – 482 mm


* folding: 40 –130, perforating: 40 – 200, scoring: 120 – 250, punching: 60 – 120

Technical Data* | Roll to Sheet, Direct Mail CS8


Web width:* 8” – 20.5” 203 – 520 mm


Paper weights: 16 – 53 lb bond 60 – 200 gsm (max. 300 gsm)

Final format length:** 5.5“ – 62“ 140 – 1575 mm



** with chip-out

Buckle Folder

Highest fl exibility with Folder/Merger Production of direct mails and selfmailers from pre-printed roll to

folded end-product. Mail pieces are dynamically perforated or

creased in both cross and vertical direction using a DP8 dynamic

processor with optional punching. The paper web is linear merged

or fold, registered superimposed in a WF8/WM8 web folder/merger.

A CS8 cutting module performs cross-web chip-out before the sheets

are presented in-line to the folding machine. The compact new WI8

web inspection system employs state-of-the-art CIS technology (contact

image sensor) for quality monitoring (color, register, codings, variable

data, etc.) while production is in progress.

Stacker LS8

Dynamic Processor

DP8

Web Merger

WM8

Web Inspection

WI8

Length- and Cross

Cutter CS8

Length- and Cross

Cutter CS8

Unwinder

UW8

Unwinder

UW8

Web Folder

WF8

Dynamic Processor

DP8

10 Premium photo book Soft cover book Hard cover book Up to 4-up book production

Roll to Roll – Non-stop SolutionRoll-to-roll high performance production. On-the-fl y roll change on the

new RS8 Roll Splicer and new TR8 Turret Rewinder. Designed for web

speeds of up to 243 m/min. Non-stop roll change in a wide variety of

paper weights ranging from 50 to 300 gsm. Increase in productivity

of up to 30 percent compared to manual roll change, depending on

print speed and roll length. Non-stop feature and paper waste

depending on printer model.

Technical Data* | Roll to Roll Non-Stop Solution

Max. roll diameter: 50" 1270 mm

Roll weight max.: 2000 lb 907 Kg

Web width: 11” – 22” 279 – 558 mm



Photobooks

Hard- and Softcover

Manuals

Publishing

Non-Stop

Roll Splicer RS8

Printing System

Non-Stop

Turret Rewinder TR8

11 Folded / stacked book signatures Thread sewn book binding Optional inline perfect binding

Loose Leaf Book Block Production with Roll to Stack Line The modular Hunkeler roll to stack solution for stacked sheet output

with continuous feed digital printing systems. Innovative non-stop

stacker with rotary single cut sheeter or variable chip-out double cutter

for full bleed products. For example, cleanly offset-stacked sheets

can be output for further downstream processing, such as perfect

binding. Loose sheet offset stacks from 1-up to 4-up production.

Flyfolder Book Solution The Flyfolder book solution is an equally innovative and revolutionary

simple concept for modern Book-on-demand production. The format

change-over between 4-page and 6-page signatures is fully automatic,

which means without any manual intervention, «on the fl y».

• Book of 1

• Fully automatic changeover between 4- and 6-page signatures

• Automatic change of book length and book thickness

• Excellent Book block quality thanks to book block gluing

Technical Data* | Loose Leaf Book Block Production


Web width: 8” – 22.5” 200 – 571 mm



Stack height: up to 10“ up to 254 mm

Format length: 5“ – 19“ 127 – 482 mm


Applications: 1up – 4up

Options: Vertical peforations in CS8 for book signatures or

tear-off perforforation, Autoregister, Dyna-Cut, Tracking*

Technical Data* | Flyfolder Book Solution


Web width: 17” – 19.5” 432 – 495 mm


Paper weights: 47 – 68 lb book 70 – 100 gsm

Cut length: 7“ – 14“ 178 – 356 mm

Performance: up to 600 delivery cycles per hour

Options: Front/Back verifi cation, Tracking

Longitudinal

Perforator LP6Flyfolder FB6Star Wheel Delivery

SD7-II- Flyfolder

Sample Workfl ow:

Automated change-over

StackingStacking GluingGluing

Folding Folding

Cross cutting Cross cutting

Turning Turning

Cross Cutter CS6-HS

Separating

Linear cuttingCross cutting

Sample Workfl ow:

3-up production

Stacker LS8

Printing System

Offset Separator SE

Web Buffer

WB8

Web Inspection

WI8

Stacking

Folding

Perfect Binding

Book Block Destacker

Longsheet-tray/

stack delivery TB8

Vertical perforations in cutter CS8

Length- and Cross

Cutter CS8

Unwinder

UW8

Unwinder

UW8

12 Thread-sewn book binding Soft cover book Front/ Back print verifi cation

Production of high-quality softcover and hardcover books In-line premium quality book production from the printed roll.

The paper is fed to the thread sewing machine from the new UW8

unwinder and through the Generation 8 CS8-I cutter. The Universe

Web book sewing machine performs several processes on the fl y.

These are creasing, folding, collecting folded sheets in 8, 12, 16 or

more pages to form one signature, as well as stitching and output.

All process steps are executed one after each other. The book blocks

are then fed into a multifunctional book production line.

Technical Data* | Book Solution (thread sewing)


Web width: 8" – 22.5” 200 – 571 mm

Format length:* 5.9" – 16.5" 150 – 420 mm


Production speed:* 436 ft/min 133 m/min

* Depends on book thickness / page count per book

Catalogues

Magazines

Booklets

Optional inline perfect binding

Publishing

Length- and Cross

Cutter CS8

In this machine, the hardcover preparation is performed by applying

cover sheets and gauze or in the case of paperback production,

with the softcover. The line is completed by the three-knife trimmer,

that features automatic size change without changing parts.

Unwinder

UW8

13

Output SolutionsPossibilities:

Pre-glued book blocks with SD7 Budget Binding High performance robot system Stack separator / Destacker

Technical Data* | Book Block Solution with SD7-II


Web width: up to 30” up to 762 mm



Folds: 1 to 2 plow folds (2 to 4 layers)

Format length: 7 – 14“ 178 – 356 mm

Book block thickness: up to 2“ up to 50.8 mm

Stack height: up to 4 3/4“ up to 120 mm

Productivity: up to 600 delivery cylces per hour:

- for format 6x9“: up to 4100 book blocks with 96 pages

- for format DINA5: up to 4500 book blocks with 96 pages

- for format DINA4: up to 2400 book blocks with 96 pages

Options: Dyna-Cut, Tracking

Inline Solution Book Solution:

High-performance Book Block Solution with Star Wheel Delivery The modular book solution for the production of glued book blocks

inline or offl ine for continuous digital printing systems up to a paper

web width of 30 inches. Processing of 4, 6 or 8-page signatures

with quick setups and format changes. The high-performance cross

cutter CS6-HS and the star-wheel delivery SD7-II guarantee non-stop

production up to 200 m/min (656 fpm) with over 600 output cycles

per hour. In one stacking cycle, several book blocks are delivered.

The system is characterized by modularity and fl exibility coupled with

simple and safe handling for further processing thanks to integrated

book block gluing and perfectly fl at book stacking.

The book-on-demand line can be used as a fl exible near-line

solution or as an inline system and is designed for the low to

medium volume segment.

Plow Folder PF7

Star Wheel Delivery SD7-II

Transport Belt

Book Block Destacker

Cart Solution

CustomizedRobot Solution

Web Buffer WB8

Printing System

Cross Cutter CS6-HS

• High availability of the system

• Non-Stop high performance system for continuous production

• Automatic change of book length and book thickness

• Excellent Book block quality thanks to book block gluing

Roll Splicer

RS8

14 Pre-glued book blocks with SD7 Dynamic book length Dynamic book thickness Thread-sewn book binding

Hard- and Softcover

Thread sewing

Budget Binding

Signature folding types: Number of pages Signature width Max. paper weight Stack

Parallel fold 4 5 – 10.5“ 150 gsm 1-up

Roll fold 6 5 – 10“ 105 gsm 1-up

Double parallel fold 8 5 – 7.5“ 80 gsm 1-up

Loose leaf 4 5 – 17.5“ 100 gsm 1-up

Books on Demand, variable format sizesThe Hunkeler book block solution is distinguished by high fl exibility,

fast and easy changeover, and excellent book block quality. Books are

produced on demand in variable format sizes, thanks to fully

automatic longitudinal format changeover, a high-performance

trimming module and a unique star wheel delivery system.

The PF7 plow folder processes paper webs up to 30 inches web

width into 4-, 6- or 8-page signatures.

Publishing

The integration of the production line into a JDF/JMF workfl ow is

possible on a customer-specifi c basis. The glued book blocks assure

simple, secure handling for post-processing. An on-board tracking

system monitors for document integrity. Book blocks will be perfect

bound nearline, with a barcode checking system to insure proper book

block to cover matching. The system will also support two alternative

fi nishing processes. The PF7 will also glue «budget bound» brochures

and books, a low-cost approach for short shelf-life products.

15Perfect-bound books without milling Budget Binding Loose leaf book stacks Front / Back print verifi cation

Stacking

Turning

Cross cutting

Loose LeafLoose sheet stacks for thread sewing or stitching

GluingCross cutting

Perforations

Folding

FoldingStacking

Turning

Folding

Folding

FoldingCross cuttingCross cutting

Double parallel fold8 - page signatures

Gluing

Cross cutting

Perforations

Perforations

Folding

Folding

Stacking

Turning

Folding

Perforations

Folding

Cross cuttingCross cutting

Gluing

Roll fold6 - page signatures

Gluing

Cross cutting

Perforations

Folding

Stacking

Turning

Parallel fold4 - page signatures

16 Stitched brochures Budget bound brochures / books Brochure with integrated vouchers Inline saddle stitching / trimming

High Performance Booklet Production Full-color personalized brochures with a variable number of pages.

The solution for high speed production of examination brochures,

leafl ets, manuals, direct mailers, and other saddle-stitched products

from a roll. Optionally the line can be equipped with the dynamic

processor DP8, and cover and sheet inserting. Process includes the

paper web feeding from the Unwinder UW8, cross cutting in the CS8

and gathering, folding, stitching, trimming in a saddle-stitching system.

Trimmer

Booklet / Manuals

Examination brochures

Voucher booklets

Commercial

Unwinder

UW8

Length- and Cross

Cutter CS8

Horizon Stitchliner

Technical Data* | UW8 - CS8 Booklet Production Line


Web width:* 11” – 20.5” 279.4 – 520 mm

Cut length: 8.3 – 13.7“ 210 – 350 mm


Paper weights: 35 – 140 lb offset 52 – 210 gsm

Productivity: up to 6000 booklets per hour, format A4, 24 pages

* Depending on stitcher

Options: Cover and Sheet inserting unit, Dynamic processor DP8, Dyna-Cut

17 Additional books with Combi Front / Back print verifi cation

Booklets and Books Combi-Solution With this combined solution it becomes possible to produce saddle-

stitched brochures or loose sheet stacks for perfect bound books.

The centerpieces of this digital production line are the CS8 Cross

Cutter and the Overpass unit. The paper web is cut into single sheets

by Hunkeler‘s precision rotary cutting system. The Overpass unit

allows quick and easy diverting of the output to the inline saddle-

stitching system or to the conveyor belt for stacked book blocks

(e.g. for transfer to a near line perfect binder).

Technical Data* | Budget Binding Solution with SD7-II


Web width: up to 30” up to 762 mm

Format length: 7 – 14“ 178 – 356 mm



Productivity: up to 6'400 booklets per hour, format A4, 24 pages

Options: Dyna-Cut, Tracking

Printing System

Web Buffer WB8

Stacker LS8

Offset Separator SE

IBIS Stitcher/Trimmer Overpass unit

Plow Folder PF7

Star Wheel Delivery SD7-II

Web Buffer WB7-30

Printing System

Glued Booklet and Book SolutionThe high performance Hunkeler brochure solution for the production

of variable on demand booklets offl ine or inline with continuous feed

digital printing systems. The optional Budget Binding device in the

Plow Folder book line enables the production of a completely glued

books or brochures without cover in just one process step. This pro-

duction method is ideally suited for products and applications that are

only used for a short time, e.g. examination documents or visa forms.

Dynamic glued brochures Examination Booklets

Cross Cutter CS6-HS

Length- and Cross

Cutter CS8

Unwinder

UW8

Unwinder

UW8/UW7

Technical Data* | Combi-Solution Books and Booklets


Web width: 8” – 22.5” 203 – 571 mm



Format length:* 5“ – 14“ 127– 482 mm


* 19" with LS8 stacker / 30" (B2) with LS8-30 stacker

Options: Cross cut with chip-out, Dynamic processor DP8, Dyna-Cut, Tracking

18

Hunkeler DocuTrimIn the high-performance range, printing systems only reach their full

potential with effi cient fi nishing systems. The Hunkeler DocuTrim is a

multifunctional system for online sheet processing that satisfi es the

requirements of the latest generation of printers. It produces online on

sheet-fed printing systems and also works offl ine. With its individually

combinable cutting, perforating and creasing in the dynamic multi-

processor (DMP), the system already addresses the market require-

ments of tomorrow. It enables the cutting of various formats and positi-

on-independent slit cuts and chip-outs. Thanks to the system‘s modular

structure, the wide range of solutions can be individually extended.

Technical Data* | DocuTrim

Production speed: 12.000 Sheets/h A4, B4, SRA4

10.000 Sheets/h A3, B3, SRA3

Sheet format Input: min. 180 x 152 mm (H x W)

max. 520* x 520 mm (H x W)

Sheet format output: min. 148 x 105 mm (H x W)

max. 520 x 520 mm (H xW)

Stack height up to 220 mm

Side trimming: 6 – 25 mm

Gutter cut: 6 – 12 mm

Perforation tools: Horizontal perf. 0 – 6 Pcs. | Vertical perf. 0 – 6 Pcs.

Paper weight: 60 – 250 gsm*

*certain limitations for formats and papers apply

DocuTrim offline configuration with pile feeder

DocuTrim

W

W

H

H

Statements

Commercial

Mailings withmixed paper

Universal Sheet Finishing

Pile Feeder

* *

* Optional Interface to folder or booklet-maker

Configuration left

Inline Offl ine with Pile feeder

DMP 2. Slot

DMP 1. Slot

DM

P 2

. S

lot

DM

P 1

. S

lot

DMP 2. Slot

DMP 1. Slot

DM

P 2

. S

lot

DM

P 1

. S

lot

DocuTrim online with Digital Printing System

CuttingPrinted sheets can be cut into a number of smaller sheets, collated

and placed in groups as an offset stack. With bleed-off applications,

the net format is achieved with a cut-out.

Dynamic perforationDynamic perforation can be carried out with horizontal and vertical

lines. Up to 6 vertical and 6 horizontal perforating tools can be used

for creating a different variety of perforation patterns. The patterns

can be static or can be dynamically triggered by a data matrix code.

1

1

2

1

1.

2.

3.

1 2

19

1

2

1

2

DocuTrim Printing System

20 High availability of spare parts Worldwide service network Hotline and Remote Assist Latest support technology

The right decisionWith your decision to go for a Hunkeler production systems you

already have taken the fi rst important step a productive system with a

high availability. The next step to secure reliability, high productivity

and a long service life is to cover all your service needs.

Combine the service products that best match your needs to secure

your ability to perform and to achieve optimal availability.

Modular and individualized serviceService products that are tailored to suit customer needs and

complement each other can be combined into an individualized

service package, thereby ensuring outstanding availability at a great

value – day after day.

Service products in all important phasesWith our service products, you benefi t from expert support in all

phases. With the “huncustomer” range of services, you have a strong

partner on your side.

Remote Assist A “remote connection” makes it possible to give external Hunkeler

experts secure access to your Hunkeler system. The remote

connection enables rapid error analysis, troubleshooting, data

backups or simple production support. The customer is fully

integrated into the process at all times. In other words, access is

controlled by the customer, who can terminate connection whenever

desired. Today, Hunkeler Remote Assist identifi es problems online

and gives you assistance as if a technician was on site. No matter

where your system is, our expert service team is always close at

hand.

Hunkeler Remote Assist is a complete package of various online

services.

Hunkeler Service 4.0

Immediate expert-support worldwide

Greater Effi ciencyhigher productivity

More profi t thanks to higher availability

20

Service

21

Hunkeler Workfl ow Manager – HWMOur software system for production planning and

process optimization

With the Hunkeler Workfl ow Manger HWM, modules and lines are

networked so that jobs can be produced optimally. The selected

apps support the fast and easy creation of productions through a

visual display of the print formats including register marks and 2D

codes. Faster job and line set-up increase effi ciency and fl exible job

assignment leads to greater product diversity.

The product-oriented job defi nition and simple operation through the

graphical editor offer unlimited possibilities without job restrictions.

Our job defi nition workfl ow becomes simple and the job data is

automatically and correctly generated.

The jobs can be created directly on the line or conveniently in the

offi ce, for example in print preparation and sent to the corresponding

lines. This signifi cantly reduces setup work and speeds up the

production of print jobs.

Hunkeler is constantly working on further apps that offer the customer

added value and can be installed on the HWM at any time.

The Hunkeler Data Capture HDC software is used to pass Hunkeler

machine data to third party systems. Hunkeler is collecting operating

data from its controllers and is making this data available for retrieval

to 3rd parties with a web server or a MQTT Broker.

Functionality

The data supplied by the line controllers is collected by the Hunkeler

Data Capture HDC and made available to external display and

analysis systems through a web server or MQTT Broker.

Analytics requires the Hunkeler Data Capture.

Hunkeler Data & Analytics

Line Line

Analytics

Data Capture

Third-party analytics system

Production data acquisition

Open interface for integration

Operating data

Reports

Workfl ow ManagerWorkfl ow Manager

22

Web Inspection System A web inspection system checks the quality and

content of the printed pages in terms of colors,

positions, contours, smearing, jet-outs, etc.

State-of-the-art digital contact image sensor tech-

nology scans the entire width of the paper web,

creates high-resolution images of the printed

image and compares these with the ‘golden sam-

ple’ to carry out many different kinds of quality

and content checks. The system ensures

consistently high print quality for a diverse

range of applications.

Printing and content errors are identifi ed at an ea rly

stage to trigger immediate action, reducing both

downtime and paper waste.

WI8 Web Inspection System The Hunkeler Control Platform represents a high-performance system

for production monitoring and quality control. With the WI8 Web

Inspection system you can check quality and content of the printing

on each page in terms of colors, positions, contours, smearing, jet-

outs, data validation, etc. It is always possible to update it with new

functions and extend it to a complete tracking solution.

Simplex and duplex colour variants The system can be integrated as a simplex and duplex colour variant.

Due to the very compact design, this can be integrated in various

modules or even in printers. Alternatively, it is also available as a

stand-alone solution.

The basic equipment includes the CIS (Contact Image Sensor) scan-

bar per side, a 22" wide multi-touch LCD operator monitor and the

controller box.

Touchscreen for operation

Controller box

CIS Scan bars

IPIIntelligent Print Inspection General Web

Inspection System

Does not need «golden sample» Needs «golden sample»

Data Matrix Code(Decoding & Verification) Printer calibration

Inspection of variable data book/transactional

Needs dedicated calibration page

WI8Camera System

TrackingHunkeler Control Platform – HCP

• Duplex or Simplex• Standard available width: 22" • 14", 30", 42" available

upon request

Web Inspection

Web Inspection WI8 with printer integrated Web Inspection WI8 as stand-alone solution

Web Inspection WI8 with Dynamic Processor DP8 Web Inspection WI8 with Length- and Cross Cutter CS8

Dyna-Scan

Hunkeler's versatile dynamic function Dyna-Scan offer dynamic scanning of variable sheet lengths with automatic

changeover during ongoing production. The result is noticeably higher fl exibility and profi tability.

Intelligent Print Inspection – A new dimension in print inspection

IPI stands for Intelligent Print Inspection and enables a new way of performing print inspection. In traditional print

inspection, the operator creates the template for image matching (Golden Template). A number of features to

be checked are selected on a printed page that has been found to be “good”.

IPI opens another way to create the template for image matching: Instead of having the template set by the

operator, the IPI system uses the raw print data directly sent from the printer controller to the inkjet print heads.

In transactional printing, errors in the printing of variable data can be detected without, for example, the address

information being known in advance. Furthermore, it is possible to detect print errors in graphics and images, even

if they occur only once in an entire print job.

Prepress

Print Server

Datastream

Printer

Paper web

CISScan Bars

– =

ControllerBox

Direct comparison of virtualimage to printed image

23

24 Check for missing pages, documents and jobs

Check for correct sequence (front-back verifi cation)

Check for duplicates/ incorrect pages, documents, jobs

Check for correct print direction

Tracking SolutionThe tracking system monitors ongoing production

in terms of completeness and accuracy. The

consistency of ongoing production is constantly

compared with the target data and missing pages

or duplicates are identifi ed. Defective products

can be automatically fed out of the production

workfl ow and missing documents reprinted,

thereby facilitating fully automatic operation

and rendering manual controls superfl uous.

Standardized interfaces enable communication

with superordinate systems (host cumputer) to

take place and support monitoring across mul-

tiple lines and even multiple production sites.

LOG

CONTROL FUNCTION

BASIC INTEGRITY CONTROL

CONTROL FUNCTION

PRODUCTION LOGGING

TRACKING FUNCTION

TRACKING

Line Controller

Control & Tracking Solutions

25

Basic Integrity Control

• Page sequence control within the document

• Document sequence control within the job

• Document completeness control

• Front to back matching

• 1-up and/or optional 2-up production handling

Options: Stop the line, stack separation

Production Logging Basic Integrity Control

• Simple logging of results from Basic Integrity Control

• Share logging with external system (File based)

Tracking Production Logging Basic Integrity Control

Site Manager, tracking server with full tracking scope

• Duplicates detection

• Missing documents detection

• Full production tracking

• Production reporting

• Reprints generation

Options: Stop the line, stack separation, dynamic rejects

Check for correct enclosures, covers etc.

Production Logging Document error reject Flawless end products ready for shipment

Cont

rol Fu

nctio

nsTr

ack

ing S

olu

tions

LOG

CONTROL FUNCTION


CONTROL FUNCTION


CONTROL FUNCTION

PRODUCTION LOGGING

CONTROL FUNCTION


CONTROL FUNCTION

PRODUCTION LOGGING

TRACKING FUNCTION

TRACKING

Customer Host

Customer Host

Site Manager

Single Line Tracking Multi Line Tracking

Line Controllerwith integrated Site Manager

Web Inspection

Web Inspection

Line Controller

Line Controller

Line Controller

Line Controller

25

26

Web Inspection WI8

Stacker LS8-30Buckle folder

Offset Separator SE

Overpass unit

Pharma package leafl ets from the rollWith the Hunkeler Generation 8, production from the roll to the

fi nished folded package leafl et. Different end formats up to 30 inch

format length (B2+ sheets) possible. As an option, single-sheet

stacks up to a height of 250 mm can be stacked or single sheets can

be fed to a folding unit via the sheet overpass. In the CS8 cutting

module, inkjet printer color bars can be cut out automatically

and the format length can be changed dynamically from sheet to

sheet (Dyna-Cut). In the offset separation unit, sheets can be offset

laterally in run at full speed.

With the optional Hunkeler web inspection system WI8, even

the smallest defects can be detected and automatically rejected.

Details on the pages web inspection and tracking solutions.

Integrated diverterOffset stacking Variable chip-outB2+ sheet stacks with LS8-3026

Technical Data* | Pharma package leafl ets from the roll


Web width: 8” – 22.5” 203 – 571 mm


Paper weights: Light weight paper up to:

27 lb offset/book (max. 110 lb cover) 40 gsm (max. 300 gsm)

Format length: 5“ – 30“ 127 – 762 mm


Options: Dyna-Cut, Tracking, Longitudinal perforation, Folding machine

Special Solutions

Unwinder

UW8

Length- and Cross

Cutter CS8

Web-Cleaning PEM

The paper dedusting unit iPEM and PEM removes the paper dust which adheres to the

paper-web and which would also foul the follow-on machines and digital printer. It works

with compressed air. The micro particles are removed contact-free from the paperweb and

are then collected in the exhaust air bin. If the speed of the web is low, the laminar fl ow is

activated, which creates an optimal operation independent from the speed of the web. The

sharp air jet takes off the dust from the surface like a planer. The paperweb is cleaned on

both sides in one process.

Available as an option on the unwinder UW8 (iPEM) or stand-alone (PEM).

Compact suction unit, mobile with integrated fi lter device

The HKU 2000-N nonstop is equipped with a chopper for the extraction of paper waste

cut-offs and endless strips. All machines are compact, mobile, and operate entirely in a

negative pressure mode for the extraction and fi lter devices. The dust-laden air is cleaned

in the fi lter unit, then returned to the production room; dust and paper cuts-offs fall into the

large volume container below the suction unit. In order to avoid compromising the operating

process of the production machines, they are equipped with a slider system, which allows the

full material container to be emptied during operation.

The module is also available as HKU 2000-B without slider system.

Ideal suction unit for Hunkeler Gen8 cutting lines.

Compact suction unit with high suction power

The HKU 1250 compact suction unit can be used for small dust quantities as well as for the

suction of remaliner punching (confetti). The mobile suction and fi lter unit is characterised

by high suction power, high effi ciency, low energy demand and low operating noise.

Ideal suction unit for Hunkeler DP8 with fi le holes and PP6.

Connection to a central extraction system

The central extraction system collects the production waste material directly from the Hunkeler

cutting modules. As an option, the endless edge strips can be perfectly cut by a shredder for

transport in the piping system. The shredder is equipped with a communication interface for

connecting the central extraction system and the Hunkeler production line.

Further information for central extraction systems of the Hunkeler systems:

www.hunkelersysteme.com

Hunkeler supplementary solutions Web cleaning and paper waste extraction systems

Functionality

Airfl ow/ Negative Pressure Bernoulli Principle Bernoulli Principle Contactless suctioniPEM PEM

27

Reaching the summit together

www.hunkeler.ch | [email protected]

Hunkeler AGBahnhofstrasse 31CH-4806 Wikon

Phone: +41 62 745 61 61Fax: +41 62 745 62 [email protected]

Hunkeler Deutschland GmbHBergstrasse 15D-82024 Taufkirchen

Phone: +49 89 614 1590Fax: +49 89 612 [email protected]

Hunkeler Far East Ltd.Room 1001, East Town Bldg.41,Lockhart RoadWanchai, Hong KongPhone: +852 2528 4082Fax: +852 2866 [email protected]

Digital: developed to meet specifi c needs: Solutions from Hunkeler

for pre- and post-digital printing are available for almost any imaginable

application. Publishing applications for small to medium runs, computer centers,

transactional and transpromo, security printing or creative direct mailing: we

have high quality solutions for all of these applications. A small sample of the

larger range of our potential end products are shown in this brochure.

Validated with all major printing presses.

*All solutions and technical data subject to change. Performance depends on

running confi guration, application, and substrates (paper).

Technical data will change with different running confi gurations like

bypassing a module, different non Hunkeler post-fi nishing solutions, etc.

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