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The joint statement from the companies says, ‘Hunkeler and Müller Martini have been very close for many years. The long and successful history began during the Second World War, when Hans Müller worked for Hunkeler as a mechanical engineer before setting up his own business in 1946 and founding the company Hans Müller / Grapha. These good relations have been maintained for decades. The local proximity in the Zofingen region and the already existing and successful partnership in the machine and component business form an ideal starting point for even closer cooperation in the future.

‘By joining forces, both companies see great opportunities to bundle their innovation activities and to serve their global customer base even better in the future through joint sales and service activities. The two owner families have therefore decided on this strategic transaction that led to the acquisition of Hunkeler AG by Müller Martini AG.’

Bruno Müller is quoted as saying, ‘The graphic arts industry is constantly changing and regularly calls for new innovations. By combining the key components of the two companies, such as personnel, expertise and technology, we will be able to serve our global clientele even better with innovative solutions in the future.’

The following is attributed to Stefan and Michel Hunkeler: ‘There is a long-standing partnership between Hunkeler and Müller Martini and a regular exchange. The opportunity for the merger is currently greatly beneficial for both partners and our joint customers, as it will result in considerable advantages in a combined enterprise. This is also a strong commitment for the Zofingen region.’

It is not clear what the implications will be for the companies’ separate operations across Europe and beyond, or their relationships with distributors and customers in countries where there are no direct subsidiaries; Hunkeler is distributed in the UK by Friedheim International, for example, while Müller Martini has its own UK operation. The future of the popular and well-attended Hunkeler Innovationdays event, which focuses on high-end inkjet printing systems and was last held in February/March 2023, and not due to recur until early 2025, is also unknown at this point.

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The new Antaro perfect binder is available in two versions. It is described as a compact perfect binder platform that is suitable for highly flexible use. In on-demand applications, it can produce digitally-printed single books at up to 2000 cycles per hour, an output rate that Muller claims no other machine currently on the market can match, and with the lowest staffing levels. In the conventional version, it delivers up to 4000 cycles per hour.

The Antaro models enable digital nearline or inline production as well as conventional production, and so cater for a wide range of customer requirements. Muller says it also offers a high level of investment protection, because the system can be expanded and adapted on a modular basis.

Antaro Digital offers fully automated single-book production with manual feed or inline connection to the SigmaLine Compact digital book production system (see below). With six clamps, up to 2000 individual books can be produced per hour. The regular Antaro version can achieve 4000 cycles/hour in combination with a gathering machine and a three-knife trimmer.

The units’ compact design is said to reduce floorspace and to require fewer than half the number of operators of alternatives. A swing clamp system allows continuous production of books with automatic adjustment for up 20mm thickness variance from book to book. Both EVA and PUR glues are supported, and a newly designed drum cover feeder and cover buffer for the digital version plus barcode reading ensure matching of covers to inners.

Muller is also now shipping the SigmaLine Compact book block system for use with roll-fed digital presses. The unit has a variable configuration but occupies only 40sqm of floor space. Muller says it can change folding schemes – from three across to four across, for example – in 10 seconds, increasing productivity and reducing set-up and changeover times via the Connex workflow. Waste generated during format change is limited to a few metres, and as with the Antaro units, less operator supervision is required.

The SigmaLine Compact handles rolls up to 22.5in (571mm) wide and embodies Muller’s ‘air knife’ folding technology found in the larger SigmaLine III units. It is suitable for producing blocks for softcover, hardcover, thread sewed and saddle stitched products.

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The new software runs as a module within Muller’s Mpower portal which is  provided free of charge with every new machine and allows production to be analysed in a targeted manner, optimisation potential for production to be identified and planning reliability to be increased. Promoted as an important element of Muller’s Smart Services, via access to production data stored in the cloud via Internet access from PC, tablet or smartphone, Connex Info Cloud is said to reduce costs and increase productivity.

The three modules are the dashboard, analytics and reporting. The first enables real-time evaluation of production data including machine status, production speed, job quantity and scrap quantity. A wide range of key performance indicators (KPIs) – such as average cycle rate, production performance and machine availability percentage – are displayed on ’tiles’ that can be freely configured, customised and arranged. The dashboard is customisable to each user.

The analytics module offers targeted evaluation of the data according to individually configurable filters and makes it possible to analyse the data in detail over a defined period and to identify optimisation opportunities. Any time span can be selected and machine, job or shift selections can be refined. Reporting provides accurate data on production with bar and pie charts. Reports on lines, time and jobs can be generated and filters can be used to create the desired reports.

Muller Martini customers may choose any selection of the modules.

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The company says the new system, which was demonstrated at the Hunkeler Innovationdays event at the beginning of March, offers a hybrid solution for products printed digitally, analogue or by a mixture of both, and can support runs lengths down to one. It features a redesigned pass-through folder which provides the link between the digital feeder and the saddle-stitcher. Its new operating technology is complemented by an Asir Pro camera for code reading and/or image comparison, and a completely new infeed that can now also be equipped with creasing.

The stitching machine adapts to the product thickness and controls the stitching wire length fully automatically from product to product. The automated wire feed gear has now been installed outside the stitching centre, improving operability and accessibility. The three-knife trimmer also adjusts automatically to the product thickness. Cutting takes place with the product stationary, for higher cutting quality.

The Prinova Digital’s has a new user interface with context-sensitive displays and an ‘innovative operating concept’ claimed to shorten processes, via a large touchscreen; up to two external screens are supported for displaying production data. In digital production, the workflow view shows the next job on the reel, which formats are pending, or whether wastage has occurred.

The redeveloped feeder section uses individual feeders with servo drives, with up to 14 individual feeders enabling hybrid production. This can be managed by a single operator thanks to a high loading height, and can be tilted, enabling several application options at the same time, such as manual loading or setting the optimal discharge height for signatures.

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Over the years, Hunkeler’s eponymous Innovationdays event has become an important platform for the continuous feed digital printing industry to coalesce around, attracting all the major press manufacturers as well as a variety of software developers, and providing a highly focused gathering for this part of the digital printing industry.

Almost 100 partners will also present their latest products in all areas of digital printing and processing in Halls 1 and 2 at the Messe Luzern. These partners include all the major manufacturers of printing and finishing systems, software developers and providers of finishing materials and consumables. As in previous years, many of the exhibitors will use the event to offer a European or global premiere of their latest innovations. A selection of these is listed below.

Exhibitor highlights

Mailroom automation for transactional print and direct mail will be the focus of the Bowe Systec stand, with a particular focus on the Fusion Speed inserting system, which will have its first ever live demonstration in Lucerne. The inserter can process up to 30,000 envelopes per hour and will be demonstrated in conjunction with Bowe’s Boxit system for automatic filling of postal trays. The company will also explain how upstream and downstream stages can be streamlined as part of an end-to-end automation concept.

Canon is playing its cards close to its chest but has promised two product news announcements at the event which ‘build on Canon’s expertise in inkjet’. Topics to be discussed also include the company’s strategy and how technology and business innovation can be harnessed together help ‘future-proof’ PSPs’ operations; the focus will be on publishing, promotion and business communications.

Another premiere at Innovationdays will be on HP’s stand, where the recently-launched PageWide Advantage 2200 digital web press will make it first European appearance. During the four days of the event, HP will be printing different applications such as postcards, leaflets, catalogues and books on a variety of substrates on the 150m/min press. In addition, the US company will showcase automation and services solutions.

Hybrid Software Group will feature its technologies for industrial print manufacturing processes which use inkjet and other printing techniques, showcasing all its brands covering the full stack of core technologies needed for inkjet. These include colour management, high-speed Digital Front Ends and Rips, pre-press software for labels and packaging and printhead drive electronics. All the group brands will be represented: ColorLogic; Global Graphics Software; Hybrid Software; iC3D; Meteor Inkjet and Xitron.

Converting and high quality embellishment will be the theme of the Kama stand, which will feature the Servo generation of the ProCut 76 Foil. The machine suits a range of applications from die-cutting, creasing and perforating to embellishment with hot foil, hologram and relief for commercial jobs and folding cartons. It will be shown with the AutoRegister AR3, which uses two cameras to bring each sheet into position at full speed.

Kern will present the new Kern 3200 Flash, a modular multi-format inserting system designed for flexible and complex inserting jobs in the medium- to high-output range. Different configuration options make it suitable for use in transactional and direct mail. A newly-developed inserting module is said to be the only system in this performance class that can be equipped with more than one envelope magazine, allowing the system to process different envelopes job by job, without the operator having to make a physical change. The 3200 Flash can be combined with a choice of modules, including roll and single sheet feeding. It is also possible to integrate up to 16 inserting stations.

Kodak’s Prosper Ultra 520 will get its first European showing

Another European first will be the Prosper Ultra 520 web press from Kodak. To be shown with a Hunkeler unwinder and rewinder, along with the Hunkeler WI8 web inspection system, the press will print live three versions of a ‘magalog’ (blend of magazine and catalogue) with different editorial and marketing content. The application will demonstrate the Ultra 520’s ability to print heavy ink coverage on standard offset paper at 150m/min. Other finished samples from the Ultra 520 and from the Prosper 7000 Turbo press, which runs at up to 410m/min, will also be presented, along with Kodak’s Prinergy On Demand workflow software.

Kyocera will feature its TaskAlfa Pro 15000C sheet-fed inkjet press, with a focus on its sustainability credentials, productivity, output quality and media flexibility. One-to-one demonstrations are being offered. More information may also be available about the graphic-arts focused version that is understood to be in development.

Another world first in Lucerne is the arrival of the Prinova Digital Saddle stitcher from Müller Martini. The highly automated 9000 cycles per hour unit supports both digital and hybrid print production and brings Müller’s Smart Factory concept to magazines, brochures and catalogues. Developments to the Vareo Pro perfect binding line will also be shown, including a mixed mode that allows softcover books and hardcover book blocks to be produced in the same run, complemented by a new de-stacker and sorting for subsequent InfiniTrim cutting. A variety of live jobs, including all-digital and hybrid printed products, will be featured, along with the supporting Connex workflow.

Workflow developer OneVision will explain how its software allows for ‘a complete integration of company processes’ by being configured to suit existing systems. The modular middleware can automate the production process from file input through printing and embellishment and finishing, while connecting to existing print and finishing hardware and software such as MIS or ERP.

Ricoh will be making the first public showing of its Pro VC70000e inkjet press that includes a number of hardware and software features and updates which collectively increase ease of use through automation, while providing greater media and applications flexibility via pre-coating. This will be complemented by the introduction of TotalFlow Producer, which the company describes as a ‘vendor agnostic automated job onboarding solution’. The new workflow software designed to automate job intake and consolidation from multiple sources, to run automatic pre-flighting and to support personalised job upload and status portals for print clients.

Riso will feature its newest additions to the SRA3 Valezus sheet-fed inkjet line, which are targeted at production print job demands that are difficult to handle efficiently on continuous-feed presses. The twin-engined Valezus T2200 is capable of duplex printing at 330ppm. The single-engine Valezus T1200 is aimed at both short and long-run full-colour transactional printing at 165ppm. Both are equipped with feeder/stacker units for a maximum capacity of 8000 sheets on the T2200, and half that on the T2100. Both models support uncoated papers only, from 46 to 210gsm.

The Smart High Definition technology from Scodix will appear in the premiere of the Ultra 6000 embellishment press

Also making a first European appearance will be the Ultra 6000 digital embellishment press from Scodix with SHD (smart high definition) capability. It will be used to demonstrate embellishment of B1 and B2 sheets for a variety of book covers, from paperbacks to high-end jackets and Scodix says it embodies the economics and productivity to replace analogue embellishment technology whilst offering publishers greater flexibility. Examples of the SHD technology will also be shown.

Staff from Solimar Systems will demonstrate how its workflow-enhancing post-composition solutions support production printing on both cut-sheet and continuous feed devices, finishing, mailing, e-delivery and document archiving. The company is partnering with HP to show how direct mailers can save significant sums and with Screen to demonstrate dashboard tracking of incoming work and device-level ink and media consumption reporting via Screen’s Equios workflow.

W+D will use the event to launch its new BB820+, a new flagship inserter which the company says allows for the widest range of direct mail sizes, from C6 envelopes up to B4 flat packages up to 15mm thick, and which can insert at up to 20,000 piece per hour, 25% faster than the model it replaces. The new machine comes with a new rotary feeder for consistent feeding at the higher speeds and an additional servo axis for flexible and size-dependent motion control of collating track, envelope gripper transport andinsert finger.

Short-run book printing using the Sirius dry toner technology will form a major part of the Xeikon exhibit, centred on the roll-fed duplex Xeikon SX30000 press, which is also getting its first public European showing. Three high-end applications will be shown – a coffee-table travel book, a full colour tourist guide and a highly illustrated book on architecture. The SX30000 roll-fed press will be running in line with a Hunkeler Gen8 roll-to-stack solution, producing book blocks which to be bound on an offline Muller Martini Vareo Pro with InfiniTrim.

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The Horizon StitchLiner Mark III, installed by Horizon’s distributor IFS at the beginning of 2022, comes with a bleed creaser and a Horizon HOF-400 high speed feeder. The machine was brought in to replace the Duplo 5000 booklet maker and to give Pureprint an uplift of 150% in production. The company claims production levels have already surpassed predictions, reaching 200% so far.

In addition, a Muller Martini Primera high speed stitcher was installed in June 2022 to replace a Muller Martini Bravo. Running at 14,000 cycles an hour, the company is already benefitting from a 125% increase in productivity. Fitted with a cover feeder, ASIR pro camera system and a fully automatic stacker, Pureprint has also added an easy drum stitching wire system and a child friendly stitching option. This complements the businesses growing demand for children’s books and enhances their market offering, by bending the staples inwards so children can’t cut their fingers.

Craig Berresford, manufacturing director at Pureprint Group, said, ‘Our new Horizon StitchLiner Mark III has been a fantastic success with the machine running on a 24hr continental shift pattern. It’s helped us to fulfil our general commercial work and has increased our capacity in web to print work. The Muller Martini Primera has improved our productivity rates dramatically, in turn increasing our speed to market for clients.’

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