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HEIDELBERG INDIA EDGESPEAK EDITION 4 ISSUE 1 Obsessed with precision - just like you. POLAR
HEIDELBERG INDIA EDGESPEAK EDITION 4 ISSUE 1 Obsessed with precision - just like you. POLAR
HEIDELBERG INDIA
EDGESPEAK
EDITION 4
ISSUE 1
Obsessed with precision - just like you.
POLAR in the News
Online Training Program
Product Feature
Tips and Tricks
Did You Know?
Contact Details

Dear Print Industry Colleague,

We're pleased to bring you the 4th edition of POLAR EdgeSpeak. POLAR has seen two more special achievements in 2009. The POLAR L-R-137-T PACE cutter has set a productivity record of 6 pallets per hour! Also, POLAR has been ranked the No. 1 postpress firm in a survey. This has been a great ending to 2009 for POLAR and has spurred it to take even greater strides with the year ahead.

The Product Feature section talks about the Jogging System L-R-P, Cutting System L-R-P-T and the Label Systems DC-11, SC-20 & SC-21. The Tips and Tricks section explains the Align Material function, which enables automatic realignment of cutting material.

We look forward to your feedback & queries. And warm New Year wishes from all of us. May 2010 bring you plenty of happiness and success.

Mr. Saseendran Product Manager, POLAR Equipments

POLAR and Heidelberg celebrate 60 years of partnership POLAR IN THE NEWS
POLAR and Heidelberg celebrate 60 years of partnership
POLAR IN THE NEWS
celebrate 60 years of partnership POLAR IN THE NEWS A present is handed over to commemorate

A present is handed over to commemorate 60 years of business partnership.

From left to right: Alfred Henschel – Joint Managing Director, POLAR, Bernhard Schreier – Chairman of the Board at Heidelberg and Michael Neugart – Joint Managing Director, POLAR.

A family friendship led to global market leadership

During the monetary reform in 1948 and the foundation of the Federal Republic of Germany in 1949, Germany amazed the world with what was considered an economic miracle. All over the country, people were building, planning and investing, including those in the printing industry. Nicolaus Reisinger, the head of the Heidelberg sales office at the time & the Mohr family were friends; and this friendship expanded into business relations.

Both companies were exhibiting their products together at the 1949 Frankfurt Spring Fair, where Hubert Sternberg, the Director of Heidelberg at the time, came to know about the Hofheim-based company. He was impressed by the technology and wide range of functions of the cutting machines. Sternberg intended to complement his range of products and had been looking for a supplier of cutting machines for the Schnellpressenfabrik Heidelberg (Heidelberg high-speed presses factory). He recommended that the brothers Rudolf and Karl Mohr collaborate and use the sales partners together worldwide.

Now, the companies are celebrating 60 years of successful partnership! Over the decades, both companies have grown and become world market leaders. POLAR has sold more than 130,000 high-speed cutters through the distributive channels of Heidelberger Druckmaschinen AG.

POLAR felt that this was the perfect occasion to thank Heidelberg for the long lasting partnership and expressed its gratitude to Bernhard Schreier, Chairman of the Management Board of the company. Alfred Henschel summarised the mutual relation in one sentence: “This connection, which is based on partnership and friendship, is an economic success story we are always enjoying ”

is an economic success story we are always enjoying ” Back to top POLAR cutter sets

Back to top

POLAR cutter sets efficiency record A POLAR automatic cutter with only one operator achieved productivity
POLAR cutter sets efficiency record
A
POLAR automatic cutter with only one operator achieved productivity
of
more than six pallets per hour!
Last year, POLAR's L-R-137-T PACE system won the globally respected
PIA/GATF InterTech™ Technology Award in the USA. During POLAR
Technology Days 2009, this system, operated by only one person, processed a
record 43 reams in an hour – more than 6 pallets, each one metre high!
The paper was manually prepared in a jogger and then automatically loaded
through a buffer onto the rear table. Here, the material was trimmed on all
four sides and finally stacked on pallets, both through automatic processes.

Marketing Director Rolf Brand is pleased with the excellent result.

Not only is the L-R-137-T PACE cutter very fast, but it has a compact design as well, not taking up much more space than a standard system. The cutter is also very flexible - small runs and a wide variety of materials can be processed.

Michael Neugart, Managing Director of POLAR says: “With this level of efficiency we can frankly claim to be offering the world's fastest cutting system. A cycle time in four-side trim of well under 90 seconds per ream! We'd really like to see anyone else do that.”

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POLAR ranked No. 1 postpress firm in a survey
POLAR ranked No. 1 postpress firm in a survey
Back to top POLAR ranked No. 1 postpress firm in a survey After the safety check,

After the safety check, the machine gets its test badge.

A 2009 customer survey about service quality in the graphic arts industry

conducted by Hamburg-based management consultancy Apenberg und Partner ranked POLAR as the No. 1 postpress firm among nineteen suppliers in the industry.

The relevant study examined three areas – regular maintenance work, non-scheduled repair work and extraordinary services. Overall, POLAR was placed third – behind Heidelberger Druckmaschinen AG and Océ.

For Michael Neugart, the Managing Director, this is a clear confirmation:

“We know that fast and reliable service minimises downtimes and saves cost.

Therefore, we have been doing our homework in the field of service in the past years together with our business partner Heidelberg. The result of this survey confirms our efforts. As far as the small and medium enterprises are concerned, our service centre certainly ranges among the top 10 worldwide.

In 2006, we invested over 5 million Euros in this modern logistics centre in

order to ensure we will still be keeping our promise of a 25 year availability of

service parts in future. In the meantime, we have been reaching fantastic values with parts availability of 96% and up to 94% of all orders being shipped on the same day. A major factor is that all the ordering processes of our sales partner Heidelberg are integrated into our own systems. This safeguards minimum reaction times. POLAR also applies a high standard in the training of our service technicians around the world. Year after year we are training up to 500 engineers in sessions of over 2,000 man-days to ensure utmost service quality.”

of over 2,000 man-days to ensure utmost service quality.” Back to top Online interactive training for

Back to top

Online interactive training for using high-speed cutters ONLINE INTERACTIVE TRAINING
Online interactive training for using high-speed cutters
ONLINE INTERACTIVE TRAINING
for using high-speed cutters ONLINE INTERACTIVE TRAINING POLAR has an online interactive training program for

POLAR has an online interactive training program for operation of high-speed cutters. The program has been conceived in close co-operation between POLAR and the Bundesverband Druck und Medien (BVDM) – the German printing and media industry federation. The training program is of particular interest for beginners in the field of cutting - new machine operating staff, students, apprentices and trainees.

The training is highly simplified. It focuses on peripheral units, interlinking, cutting formats and sequences. The exercises guide the user through a step-by-step process – there are varying levels which help him proceed from easy to difficult cutting operations. There is also a glossary for immediate reference.

Visit the POLAR website to view the program and its features. It is sure to promote better learning among your employees.

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Label System DC-11 PRODUCT FEATURE
Label System DC-11
PRODUCT FEATURE
employees. Back to top Label System DC-11 PRODUCT FEATURE Label System DC-11 The automated Label System

Label System DC-11

The automated Label System DC-11 enables much faster and efficient inline production of bundled die-cut labels. It guarantees superior performance – of up to 960 bundles per 60 minutes, among other advantages. The menu-driven setup makes operation easier and reduces make-ready time. The label system is equipped with an Autocut 25 cutting machine, a DC system die-cutter and a single head bander.

Customer Benefits

lCan cut up to 960 bundles per hour with minimum manpower.

lOptiChange allows the operator to perform a job change in only 15 minutes.

lOnePunchRegister allows positioning of the cutting die in line with the printed image with just one punch of a button.

lUtmost cutting and die-cutting precision.

lHigh reliability in daily use, and a longer lifespan.

Automatic Cutting Machine Autocut 25

lFront side knife change with alternate frames allows preparation of the knife outside the machine.

lLateral aligning gauge, front gauge system and waste cut aligning gauge ensure high quality output.

DC System Die-cutter

lAlternate frame system (patented) with a positioning aid for preparation of the knife outside the machine.

lA centred alternate frame (patented) allows precise alignment to the right and left hand sides.

lSize adjustment of the gauge and feeder without any tools via a hand wheel (patented).

lThe stamping punch can be continuously extended millimeter by millimeter for setting the register.

lOptional: Cardboard remover (patented) allows the operator to work with underlay cartons even for log banding.

lOptional: Manual feeding of the die-cutter.

Single-head Bander

lMotorised format adjustment via a central control display.

lPrecision adjustment is carried out in case of automatic operation as well.

lAllows two separating processes per die-cutting cycle, if the pack contains two divider cartons.

lUltrasonic welding unit for single pack and log banding.

lDirect restart of production after interruption of control voltage, e.g., after hitting a light barrier.

Technical Data

Label size (min.)¹

20 × 40 mm | 0.79 × 1.57 in

Label size (max.)

170 × 210 mm | 6.69 × 8.27 in

Stack height (min.)

35 mm | 1.38 in

Stack height (max.)

120 mm | 4.72 in

Height of cutting die (min.)

50 mm | 1.97 in

Height of cutting die (max.)

100 mm | 3.94 in

Performance (max.)²

16 cycles / minute

Benchmarking

DC-M

DC-11

Number of operators

2 | 2

1

| 1

Bundles / 60 minutes

480²

960³

¹ Depending on stack height. | ² Depending on material, label size, operator. | ³ Depending on material, label size, pre-cutting, strip changes.

on material, label size, pre-cutting, strip changes. Back to top Label System SC-20 The Label System

Back to top

Label System SC-20
Label System SC-20

The Label System SC-20 is ideal for high automatic inline production

System SC-20 is ideal for high automatic inline production of square-cut labels with integrated banding. It

of

square-cut labels with integrated banding. It has an excellent output rate –

of

up to 1,296 bundles in 60 minutes. It's equipped with an Autotrim M cutting

machine and a BM-105 multi-station bander.

Customer Benefits

lPerformance of up to 1,296 bundles per hour with minimum manpower.

lGreatest cutting accuracy due to the POLAR Positioning System DPS with a mechanical positioning accuracy of 1/100 mm.

lVery flexible, thanks to easy and fast conversion.

lHigh long-term reliability.

Automatic Cutting Machine Autotrim M

lDownholder in front of the knife.

lA lateral aligning gauge at the frame and backgauge further improves the cutting quality, because strips can be precisely aligned.

lMobile aligning station (patented) on the front table for aligning the cut labels.

lOptimised lateral de-loading finger for smooth workflow and faster cycles.

Multi-station Bander BM-105

lElectronic temperature control monitors and optimises the welding process.

lFull-surface row pusher with frequency-controlled drive for smooth, trouble free workflow, and automatic speed control depending on the format.

lA movable table board (patented) closes the lower gap and ensures that the label row is perfectly pushed in. Its integrated sensor scans the format and automatically controls the pressure feet of the banding unit.

lEasy adjustment of cassette holders, because the upper and lower ones can be adjusted simultaneously (patented).

Technical Data

Label size (min.)¹

20 × 43 mm | 0.79 × 1.69 in

Label size (max.)

230 × 1,050 mm | 9.06 × 41.34 in

Cutting width in automatic mode (max.)

1,050 mm | 41.34 in

Stack height (min.)

20 mm | 0.79 in

Stack height (max.)

120 mm | 4.72 in

Clamp pressure (min.)

150 daN

Clamp pressure (max.)

5,500 daN

Banding station (max.)

18

Performance (max.)²

4 cycles / minute

Benchmarking (bundles / 60 minutes)

L-R-137-B³

SC-20³

SC-21

4

SC-2

54

Number of helpers / operators

2

|

1

1

| 1

1

|

1

1

|

1

24

labels / sheet (4×6, waste cuts)

308

314

890

 

 

96

labels / sheet (8×12, waste cuts)

635

712

2,044

855

 

192

labels / sheet (12×16, no waste cuts)

1,150

1,296

3,185

 

1,670

¹ depending on stack height. | ² depending on material, label size. | ³ including pre-cutting. |

4 excluding pre-cutting.

Back to top

Label System SC-21
Label System SC-21
| 4 excluding pre-cutting. Back to top Label System SC-21 The Label System SC-21 is highly

The Label System SC-21 is highly suitable for automatic inline production of

square-cut labels with integrated banding. It has a superior performance rate

of up to 3,185 bundles per hour - offering efficiency increased by 25% to

five cycles / minute. The label system equipment includes an Autocut 115 and a multi-station bander BM-105 - similar to the SC-20.

Customer Benefits

lPerformance of up to 3,185 bundles per 60 minutes with minimum manpower.

lUtmost cutting precision due to the lateral and front gauges.

lVery flexible, thanks to simple and quick conversion.

lHigh reliability in daily use, and longer lifespan.

Advantages of the Automatic Cutting Machine Autocut 115

lFast loading due to 120 cm/sec return speed of the backgauge.

lA lateral aligning gauge at the backgauge further improves the cutting quality, because strips can be precisely aligned against the backgauge.

lAligning station (patented) on the front table for aligning the cut labels.

lOptimised lateral de-loading finger for a smooth workflow and faster cycles.

Technical Data

Label size (min.)¹

20 × 43 mm | 0.79 × 1.69 in

Label size (max.)

230 × 1,010 mm | 9.06 × 39.76 in

Stack height (min.)

30 mm | 1.18 in

Stack height (max.)

120 mm | 4.72 in

Banding station (max.)

18

Performance (max.)²

5 cycles / minute

Benchmarking (bundles / 60 minutes)

L-R-137-B³

SC-20³

SC-21

4

SC-25

4

Number of helpers / operators

2

|

1

1

|

1

1

| 1

1

|

1

24

labels / sheet (4×6, waste cuts)

308

314

890

 

 

96

labels / sheet (8×12, waste cuts)

635

712

2,044

855

 

192

labels / sheet (12×16, no waste cuts)

1,150

1,296

3,185

1,670

 

¹ depending on stack height. | ² depending on material, label size. | ³ including pre-cutting. |

4 excluding pre-cutting.

Back to top "Align Material" function allows automatic paper alignment TIPS & TRICKS
Back to top
"Align Material" function allows automatic paper alignment
TIPS & TRICKS

Benefits

n

Makes alignment of the material after cutting easier.

n

Improves ergonomics by increasing the freedom of movement.

Improves ergonomics by increasing the freedom of movement. After every cut, the material in front of

After every cut, the material in front of the knife is shifted forward and has to be manually realigned. Usually, the operator will lock the backgauge in place

by pressing the pedal of the clamp after cutting. Then he can align the

material which has been shifted and is lying in front of the knife against the other material which is locked under the clamp. However, since he has to

keep pressing the pedal, his freedom of movement is extremely limited. The function "Align Material" is an ideal solution.

“Align Material” is an automated function. After the cut, the clamp remains positioned on the material for a preset time, which allows a convenient alignment. Once the time period has elapsed, the backgauge drive is automatically started, provided that the light barrier has not been obstructed.

In Autotrim models, the function facilitates alignment of the cutting material

against the upright table flap. The table flap is in line with the front table gauges and helps to push the material easily to the side.

Adjustable timers:

lTimers 1-8 (0.5 – 6.5 sec)

lTimer 9 (backgauge drive has to be started manually)

Availability

X

XT

Autotrim

78 - 176

115 - 176

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Did you know? Die-cutting originated during the industrial revolution. The process has been used right
Did you know?
Die-cutting originated during the industrial revolution. The process
has been used right from the mid 1800s.

Sales Support:

Mr. Saseendran, saseendran.baskaran@heidelberg.com

Contact Details

Marketing Support:

Namrta Dhar, namrta.dhar@heidelberg.com

Service Support:

A. Prabaharan, prabaharan.annamalaichami@heidelberg.com