What does it do?
The DigiFold Ultra is a creasing/folding machine that is a development of the Pro XL model, with new full bleed trim capabilities. It can slit, cut, crease, perforate and fold jobs in one pass.
VP sales & marketing, Offline Business Unit for Plockmatic Group & general manager of Morgana Systems Ray Hillhouse says: “It’s not technically a complete multi-finishing device as it cannot produce inline gutters to allow for business card production. So, we end up somewhere in between with the unique capabilities of the DigiFold Ultra.”
The Ultra’s inline slitters and cross-cutting mean it can trim sheets that are too long for standard guillotines, which typically accomodate 46/52cm max, Hillhouse explains. “This opens up applications such as full bleed trimmed six-plus panel A4 brochures, super-long ceiling banners, and more.”
When was it launched and what markets is it aimed at?
The Ultra was launched at Drupa and the first units will be available in September/October. Earlier versions of the DigiFold have been around for decades, and Hillhouse is proud of its longevity. “It has been a highly productive, preferred solution for the digital printer, but also a true workhorse for long-run offset jobs. The DigiFold Ultra adds slitting and cutting functionality, creating a unique offering unlike any other machine in the market.”
The Ultra can also handle long-sheet trimming. Hillhouse says this “ allows customers to fully leverage the capabilities of their new presses, trimming applications up to 1,300mm long and potentially reducing the need for further investment in a larger-format guillotine”.
How does it work?
The DigiFold Ultra is a compact machine, on casters so it can be moved around a factory. It is supplied with a deep-pile feeder, also on casters. It maintains the productivity of the previous generation Pro XL platform (up to 6,000sph A4 half-fold). For slitting, productivity is not affected. When cross-cutting, the paper needs to stop so full-bleed processes will be somewhat slower. Media sizes and weights are also similar to the XL platform (see specifications).
It comes as standard with dual folding knives, one DynaCreaser, two slitting knives and one cross-cut knife. Two automatically placed slitters trim off the top and bottom of the sheet and a cross-cut knife cuts the lead and trail edges, before the sheet enters the creasing and folding area of the Ultra (which is the same as the crease/fold modules in the Pro XL).
The edge-registered vacuum top feeder has a load capacity of 200mm and there’s an optional table extension for sheets up to 1,500mm. Sheet separation is controlled by optical sensor and automatically adapts to different media, weights and types. There’s an ultrasonic double sheet detector. There is also automatic feeding parameter selection based on paper size and thickness, which simplifies setup.
The creasing unit can accept standard and narrow creasing blades, plus optional cross perforation blades. An optional second creaser enables up/down creasing in one pass. Up to five rotary perforator wheels can be fitted.
Adaptive Process Control (APC) monitors sheet feeding in a closed-loop process. The Feeder continuously checks the paper float zone and automatically makes adjustments on the fly.
Other options are similar to those on the Pro XL. There are also attachments such as the Trim Waste Conveyor Belt and BST-4000 Belt Stacker which are suited to longer unattended production runs.
The DigiFold is a self-contained machine, controlled by a touchscreen, with no need (or option) for network, says Morgana. While this is fine for smaller operations, it could complicate shop floor data collection.
Does it replace anything?
DigiFold Ultra is based on the Pro XL that was introduced in 2020. However the Pro XL will continue to be built and sold.
What’s the USP?
It’s a versatile development of the popular Pro XL with additional full-bleed trimming.
How easy is it to use?
Very, says Hillhouse. “It’s a highly automated system designed with an intuitive and user-friendly UI. Key in media parameters and select from standard trim, crease and fold patterns or create custom jobs as desired.”
Morgana offers the usual operator training and service support.
What does it cost?
From £35,000 depending on configuration.
SPECIFICATIONS
Media range 0.1-0.4mm (approx 80-400gsm)
Max sheet size 38x700mm (385x1,300mm with optional table extension)
Min sheet size 93x210mm
Max load capacity 200mm
Max creases per sheet 30 (with DynaCrease tool and static creasing tool)
Throughput 6,000sph, A4; half fold, one crease only 7,500sph
Number of crease tools Up to two. One DynaCrease and one static crease optional
Minimum distance between creases 0.1mm with static crease (2.5mm with DynaCrease)
Inline perf Standard
Cross perf Optional (comes with static crease kit)
Price From £35,000
Contact Morgana 01908 608888 www.morgana.co.uk
ALTERNATIVES
The nearest equivalent systems are multi- finishers that have six slitting knives compared with the Ultra’s two, so they can produce slitted gutters for multi-up applications such as business cards. However, the Ultra offers slightly longer sheets, and greater load capacity with a significantly smaller footprint and lower price.
Duplo DC-618/DC-648 with inline folder DC-F100
Duplo’s DC-618 slitter-cutter-creaser is its entry level multi-finisher (recently replacing the earlier DC-616) and can process up to six slits, 30 cuts and 20 creases in one pass to deliver full-bleed applications up to 23 sheets per minute. It handles sheet sizes from A4 up to long-SRA3 up to 1,200mm.
The DC-648 is a more advanced model, with lots of automation and connectivity to pre-press workflows and MIS for automated setup. However its maximum sheet length is 710mm. Both models can be fitted with the DC-F1000 inline folder, which integrates with the same setup controller.
Contact Duplo 01932 263 900 www.duplouk.com
Multigraf Touchline CPC375 XPRO with folding uni
This summer Multigraf was acquired by its long-term distributor Duplo. Its CPC375 multi-finisher was launched in 2016 and updated to the XPRO with a new larger touchscreen controller in 2022. This handles cutting, slitting, perforating and creasing in the same pass, at up to 35 sheets per minute for some setups. It offers length and cross cutting, cross creasing, and timed and continuous perforation in either direction(with up to four lengthwise perfing wheels). It features bar code job set up. An inline folding unit is optional. It’s another long-SRA3 machine, with maximum lengths of 1,016mm.
Contact Duplo 01932 263 900 www.duplouk.com
