Folding becomes a part of networked production
Druck- und Verlagshaus Zarbock has made a name for itself in the commercial printing market with high performance, innovation and reliability. An offset printing company based in Frankfurt am Main, it is one of the leading companies in the Rhine-Main region, and has twice won the award “Akzidenzdrucker des Jahres" (commercial printshop of the year) with its unusual print and media products. The company is PSO- and FSC-certified and has also set a benchmark in the field of climate-neutral printing. Sustainability, ecological responsibility and Industry 4.0 are firmly anchored in the corporate ethos with solutions for digitalisation, automation and networking.
Founded in 1924 by Ludwig Henssler, the company is today run by Ralf Zarbock. It specialises in magazines, booklets, financial publications, catalogues, newspapers, flyers, expressive target-group-oriented mailings and a wide range of further advertising materials. The company employs various print finishing methods such as dispersion coating, cellophaning, embossing, punching, scoring, perforating, to name but a few. As a print and media partner, its customers include international industrial enterprises, advertising agencies, financial services providers and professional associations.
Convincing consultancy and service performance together with state-of-the-art printing and workflow solutions form the basis for the efficient and economical implementation of communication projects. Zarbock has numbered among the TOP 50 ‘green’ printshops in Germany since 2009. It uses inks based on vegetable oils in an almost alcohol-free printing process. The exhaust heat from the printing presses is used to heat the printing halls and the administration building, a photovoltaic system improves the CO2 balance and the central air compression system works with high energy efficiency. Recently, as part of the Ökoprofit project, the entire lighting system was converted to low-energy LED lamps. And the company approached the virtualisation of its EDP platform with equal drive.
When the company decided to invest in a new folding machine, one of the challenges faced by potential suppliers was the integration of the folding machine into the network. Zarbock works with the MIS system Printplus. The job information in Printplus is transferred directly to the corresponding machine, which means that at the start of production, the operator at the machine simply needs to select the associated job and download it to the machine. The machine detects the job and adjusts the automated components itself.
- "We use the Datamanager as an interface, as a translator, so to speak. We can no longer imagine working without it." Robertus Häßler, Technical Manager at Druck- und Verlagshaus Zarbock GmbH & Co. KG
As a solution, MBO offered the Datamanager as an interface which acts as a “translator” between Printplus and the machines. Datamanager first saves the data of the jobs arriving from Printplus via JDF, a standardised protocol language for job-specific data, and converts them to the machine language. The job data can then be downloaded to the machine. And this is a two-way process. The Datamanager captures actual data from the machine and makes it available to Printplus in JMF format.
The real-time data from this networked application ensures that job planners have a clear overview of the status of all jobs at all times and can carry out fine planning based on the specific situation if required. For example, subsequent jobs can be transferred to another folding machine if the original folding machine is occupied for longer than planned, ensuring that the scheduled deadline can be met.
Reduction of manual entries and automation of pre-settings
The system supports the operator at the folding machine by displaying all job-relevant information on his screen. He can load the job data and, on the basis of this data, can quickly and easily check that the correct paper pallet is in place in the feeder.
And quantity comparison, i.e. comparison of the planned job quantity and quantity of sheets delivered from the press hall with the quantity on the batch card. This prevents transmission errors. And the operator no longer needs to compile information on a print job once it has been completed. The machine automatically records the number of printed sheets and the quantity of waste paper and reports the information to the ODA of Printplus.
- "The new MBO folding machine offers the highest folding speed and optimum flexibility." Ralf Zarbock, CEO
The key factor influencing the company’s decision to purchase the MBO K8RS folding machine was a folding comparison which showed that the K8RS had not only a significantly better folding quality but also an excellent folding speed.
After a brief running-in phase at Zarbock, the MBO K8RS now has the highest capacity utilisation in the finishing process and has proved its worth in the production process with its high folding speed and wide variety of folding options. It makes just-in-time production possible, thereby saving time and storage capacity and allowing even shorter delivery times.
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