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Folding had been part of Horizon’s product portfolio since the early 1980s, when it launched a non-automated SRA3 buckle-folding machine. At Ipex 2002, the company solidified its position in the folding market with the launch of a B2 crossfolder, the AFC-544, which replaced the smaller 504 folder.

The AFC-544 was pitched at commercial printers, implants and larger print houses with established folding departments that were looking to capitalise on the growing demand for quick turnaround work.

According to Gary Hards, managing director at secondhand dealer Used Horizon Direct (UHD), the AFC-544 had a number of major plus points.

Automation
"The strength of the side frames made it a robust machine. It also had failsafe gearing for prevention of damage during jams and a gear-driven drive system. Added to that, the machine had a previously unseen level of automation with step motors," says Hards.

The AFC-544’s gear-driven system, operated through an icon-based interface, can also facilitate complex folds.
In Hards’ view, the machine should be regarded as the first serious automated B2 system that in "engineering, build terms and many characteristics, was equal to qualities found in the B1 machines".

The increased automation made the AFC-544 an easy machine for operators to use. Operators select the pattern required, input sheet dimensions and then insert the stock in the callipers.

After this point the machine does the rest. Any fine-tuning is achieved on the run and an on-board computer calculates and imposes all consequent adjustments.

Newer incarnations of the AFC-544 offer more options and more fold plates. The sheet size has also been increased to accommodate different marketplaces throughout the world. The 546, launched in late 2003, offered six buckle plates and eventually superseded the 544.

In 2004, a roll-feed version was added for longer runs. The same year also saw more options become available, such as the MKU54 mobile knife fold unit, which allowed more complex folds to be undertaken. Another knife option was the MKU54-T, a mobile knife fold unit with two crossfolds.

Calliper setting
A further upgrade on the more recent models is the calliper setting for each roller gap adjustment. One master calliper was introduced so that the operator only needs to insert one sheet of stock before the machine automatically sets up. In 2008 a larger colour touch screen was also added.

All spare parts for Horizon equipment are available from UHD and Intelligent Finishing Systems (IFS), which distributes new Horizons throughout the UK. IFS will take back older models as part-exchange and offers preventive maintenance service contracts, which are tailored to the requirements of each individual customer.

IFS has 16 service engineers with expertise in electronics and mechanical engineering, who are strategically based around the UK. UHD also operates a team of specialist engineers to refurbish and rebuild Horizon equipment.

When sourcing a used model, always make sure that you investigate the usual things, such as service history.

"Check the condition of the rollers and belts for signs of good maintenance and make sure the machine is complete with all accessories and tools," advises Hards. Prices for a used AFC-544A start at £15,000.

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SPECIFICATIONS
Max sheet size 538x750mm
Stock weight range 35-220gsm
Buckle combination Four-plate buckle
Footprint 2.7x1m
Weight 770kg
Price
Used AFC-544A: from £15,000
What to look for
Rollers/belts
Good maintenance
Complete tools