For the past 50 years, MB Bäuerle has concentrated exclusively on developing and manufacturing print finishing kit – namely folders. In the 1950s, it produced one of the first A3 table-top folding machines, and by 1985 it had made automatic folding possible years in advance of its competitors, through the use of computer-controlled fold-plates.
At Drupa 1990, MB introduced the CAS range, which proved to be a huge success with 8,000 worldwide installations by 2004. But the manufacturer didn’t stop there. The B2 prestigeFold 52 was unveiled at Drupa 2004, with a computer-controlled set-up from feeder to delivery – a machine that promised to take automation in folding to new heights.
MB folders have traditionally being integrated onto inserting lines from the likes of Pitney Bowes and Bell & Howell, so it was only logical that MB would one day have an inserting machine of its own. That day has finally arrived in the form of the autoSet 18, a high-end production machine that can run at up to 18,000 cycles per hour.
Linear flow
Although the autoSet is highly modular, it is based on a linear flow of documents and there is no change of direction from the feeding system to the enveloping station. It relies heavily on an “intelligent control system”, so automation is high on the agenda – in keeping with the MB philosophy.
“All of MB’s expertise and experience with folders has been applied to the autoSet – it is built with the same technology,” says Mike Biggs, managing director for Encore Machinery, UK distributor for MB products. “It’s fully automatic – the whole machine is set without any tools whatsoever. Everything is done from a touchscreen.”
A basic, four-station autoSet 18 will set you back anything from £200,000 upwards, but Biggs says it’s impossible to put a definitive price on it. “I don’t think there will ever be a situation where two of these machines are sold identically. They will all be configured to individual customer needs,” he says.
To substantiate Biggs’ point, an unlimited mix and match of suction, rotary and friction feeder inserting stations are available in multiples of two upwards, and there is always the option to add more at a later date. “As far as I’m aware, it’s the only inserter around that offers three types of feeders,” says Encore Machinery sales manager Paul Davidson. “Having this flexibility to handle a wide variety of stocks brings numerous advantages in the transactional mailing sector.”
Selective feeding
Such flexibility will appeal to a range of clients, from banks and insurance companies to public utilities and government agencies with high mail volumes or frequent job changes.
The autoSet’s ability to be programmed for selective feeding will attract the transactional market yet further. “If your bank statement goes through and it is in four sections, the machine can be told by a database that you are interested in golf, motorsport and fishing, so it will take from feeders one, three and seven accordingly and insert them along with your statement,” explains Davidson. “So it’s ideal for the growing demand in personalised mailing.”
Davidson says the machine is able to handle a “quite astounding” level of management information. An optional interface transfers data from the machine to a PC, allowing production speeds and output levels to be analysed. This job monitoring is also useful when it comes to isolating problems on the inserting line. “There is even a screen to monitor every servo-motor throughout the machine,” adds Biggs. “It displays their load and running times, so if there is a tight bearing somewhere, it can be located.”
The autoSet line begins with a choice of paper feeders (not to be confused with the feeders on the inserting stations). The MB-System 432 is designed for collecting and folding and can include a cutter for continuous forms, or a cut-sheet pre-loader. The MB-System 426 is for paper that doesn’t require folding and comes with a cutter or the 904 online system, used for slitting A4 cut-sheets into three documents.
Faults that occur during the work cycle are displayed on screen as icons or in plain language. The operator is alerted well in advance when the number of envelopes or inserts falls below a minimum quantity. “If there is a jam or fault on one of the sensors, a diagram of the problem area is highlighted on screen by a red ring around the fault area, and that particular guard will open,” says Biggs.
Envelope size changes are automated. The operator enters the dimensions for height, width and flap depth, the control unit calculates the positions for the envelope feeder, and the enveloping and sealing stations are automatically set up. Improperly loaded or partially opened envelopes are recognised and diverted without disrupting the job.
To take up less space, envelopes are delivered vertically into the on-edge stacker. This extends the capacity and increases the interval periods between envelope removals. Under this delivery principle, the envelopes are always in a position where they can be removed with ease, and there is no need to jog them.
Kicker device
An optional kicker device can identify postcode breaks, helping the off-loading and sorting of envelopes. Further optional devices include a collector, lay-down station, an inkjet unit, multiple diverters, postage meter modules, and loading modules for feeding systems.
The autoSet can be managed by a single operator but, if it is configured with a high number of inserting stations, a second person may be required. Released in the UK in December, the machine has been commercially available in North America and Europe for a while. “There are a number of installations in places such as the US, Spain and Germany, and the feedback has been positive enough for them to roll it out to the rest of the world,” says Biggs.
MB has a US sister company, GBR, and, according to Biggs, this was the prime reason why the autoSet was pushed to that market first. “But the UK market is still very important to them,” he adds. “The machine has already created a lot of interest here, even though we’ve not spoken to anyone about it until now.”
Based in Dunstable, Bedfordshire, Encore Machinery will hold specific parts “as needs be”, but often ships spares from MB in Germany. “If we ask MB for something before 4pm, the customer will have it by 9am the next day,” says Biggs.
The autoSet may not be on show in the UK until Ipex 2010, but there is talk of an open house in Germany next month. “People prepared to fork out £300,000-plus for a machine are also prepared to travel to look at it. There’s a super-installation in Stuttgart and we can arrange trips combined with visits to the MB factory,” says Biggs. “You can see it being built and get to know the manufacturer.”
SPECIFICATIONS
Speed 18,000cph
Max envelope size 170x250mm
Min envelope size 106x170mm
Number of stations min-max (increment)/2-unlimited (2)
Price from £200,000
Contact Encore Machinery 01582 668900 www.encoremachinery.co.uk
THE ALTERNATIVES
Pitney Bowes APS Series
The APS is compatible with all API (Advanced Productivity Input) and HPI (High Productivity Input) modules, giving secure collation speeds of up to 72,000 sheets per hour. It is controlled by the Direct Connect software platform and can be networked to enable Pitney Bowes DFWorks.
Speed 22,000cph
Max envelope size 163x292mm
Min envelope size 98x178mm
Number of stations, min-max (increment) 3-24 (3 or 4)
Price from £200,000
Contact Pitney Bowes 020 8465 4614 www.pitneybowes.co.uk
Böwe Systec Turbo 22
A standout feature of the Turbo 22 is an option called BIPS (Böwe Intelligent Productivity System), which minimises set-up times by automating job format changeover of envelope sizes. Also worthy of note is the vertical paper transport system, which allows the weightless draw-off of envelopes and inserts.
Speed 22,000cph
Max envelope size 162x242mm
Min envelope size 90x160mm
Number of stations, min-max (increment) 1-14 (1)
Price not supplied
Contact Böwe Systec (UK) 01344 462100 www.bowe-systec.co.uk
Kern K3500
The K3500 is capable of handling up to 22,000 insertions per hour, but to adapt to the widest variety of mailroom environments, speed is continuously variable. When a job is started, the processing speed is automatically adapted to the application being run. It has a number of productivity-enhancing functions, such as MailFactory, Kern’s mail traying and trendsetting software.
Speed 22,000cph
Max envelope size 175x244mm
Min envelope size 89x152mm
Number of stations, min-max (increment) 0-8 (2)
Price not supplied
Contact Kern 01489 564141 www.kern.co.uk
