The Kaufmann printing company increases competency in ... - Kolbus

KOLBUS News for the customers 5|2008
Deutscher Drucker
Trade magazine for pre-press, cross media publishing,
printing, print finishing
Deutscher Drucker Verlagsgesellschaft mbH & Co. KG, Ostfildern
Issue 16|2008
Page 1
The Kaufmann printing company
increases competency in further processing
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The new Publica perfect binding line by KOLBUS at the
Kaufmann printing company. View of the ZU 841.C gathering
machine with 18 stations.
Perfect bound products inline on their way to the fully
automatic ESM 15 insertion line by Hugo Beck
KOLBUS GmbH & Co. KG
Osnabrücker Straße 77
32369 Rahden
Germany
Tel. +49.5771.71- 0
Fax +49.5771.71333
www.kolbus.de
Growing quality awareness on part of the customer, in -
creasing unit costs in Germany with constantly decreasing
time slots: Printing companies wanting to be among the
front runners in today’s market, must have highly flexible,
complete production lines at their disposal in order to me et
the requirements in the printing industry. The Kaufmann
roller print shop in Lahr around Baden invested three
mil lion Euro in a large perfect binding line by KOLBUS,
coupled with an insertion line by Hugo Beck.
A new book bindery within two weeks? What many a person at
Kaufmann regarded as a bad joke, quickly became reality when
12 fully loaded trucks (lorries) stood in front of the company gates.
Step by step trained installation teams installed the new machine
line in a hall full of machines. For Karl-Heinz Becker, Executive
Technical Director at Kaufmann, the new ›Publica perfect binding
line‹ by KOLBUS had long cast its shadows before: »Due to the
fact that the roller is the cycle generator at our company, and we
fill large capacities with our 48 page machine, the print finishing
sector must also be able to process large-scale editions quickly.
And for this, only two to three suppliers could be considered.«
»A great help was that Kaufmann analysed the job structure for
an entire year and made this data available to our project engi -
neering department«, said Michael Klopfer, Sales Director (South)
at KOLBUS. »With the quantities resulting from the job structure,
it immediately became clear that a fast perfect binder is required
here. The faithful collaboration has paid itself off for Kaufmann
in the form of a very short planning and installation phase.«
The new machine line can achieve 10,000 to 15,000 catalogues
per hour. It consists of a ZU 841.C gathering machine with
18 stations, 12 STA 840 bundle feeders, the KM 411.C for perfect
binding with Hotmelt and PUR glue, two drying towers as well
as one HD 153.P three-knife trimmer with counted stack function
and opens completely new horizons for Kaufmann. »We manufacture
high quality catalogues for the travel sector, for furniture,
bath fixtures, fashion, mail-order and publishing house products.
This not only places demands on the colour management but also
on print finishing«, explains business partner Markus Kaufmann.
»Even the most capable book binder commissioned by us is not
as close to the customer as we are. This entails the risk that even
high-end products are ultimately supplied only run-of-the-mill.
Today, we can tell our customers: ›These things are also taken
care of at our company‹ – which represents an added value for
the customer.«

KOLBUS News for the customers 5|2008
Specialist article
›The Kaufmann printing company
increases competency in further processing‹
Deutscher Drucker
Trade magazine for pre-press, cross media publishing,
printing, print finishing
Deutscher Drucker Verlagsgesellschaft mbH & Co. KG, Ostfildern
Issue 16|2008
Page 2
1
1
State of the art touch-screen terminals for each feeder
Satisfied with the completed project, from left to right:
Timo Kollmann and Horst Heimann (Hugo Beck),
Markus Kaufmann and Karl-Heinz Becker
(Kaufmann printing company),
Wolfgang Bokämper and Michael Klopfer (KOLBUS)
KOLBUS GmbH & Co. KG
Osnabrücker Straße 77
32369 Rahden
Germany
Tel. +49.5771.71- 0
Fax +49.5771.71333
www.kolbus.de
Lastly, the project engineering team had to keep the required
flexibility and versatility of the machine line in mind. As more and
more publications want to increase their communication and ad -
vertising impact with promotions and inserts, the insertion lines
from Hugo Beck are becoming more popular. Two ESM 15 syst ems
for up to four inserts are now available to the Kaufmann printing
company at the same time. »Due to the plug and play technology,
the machine lines can be used by us ad hoc in the perfect binding
as well as wire-stitching sector. In addition, the feeders can be
used alone or as subunits with the saddle stitcher. Thanks to the
modular controlled components, the manufacturer of this flexible
peripheral technology can hook into the KOLBUS concept without
any effort. The connection between KOLBUS and Hugo Beck
works perfectly«, states Horst Heimann, Technical Director at Hugo
Beck. »The perfect bound products feed inline via a transport path
with buffer stations into the fully automatic insertion line, without
products having to be inserted manually.« This keeps the unit
prices in check. While print finishing, including the placement of
inserts and merchandise samples, frequently belongs to the most
personnel intensive departments, recently 800,000 catalogues
were produced in 10 shifts using the new KOLBUS machine line,
and this with only three machine operators per shift plus additional
personnel. »It was impressive to see how quickly the machine
line was in operation, the team was motivated because it wanted
precisely this system and it was fun to achieve this together with
KOLBUS and Hugo Beck«, said Karl-Heinz Becker. However, the
reasons why Kaufmann decided to perform their own perfect
binding in this high volume area, in the future, are also of a strategic
nature. After large-scale saddle-stitching plants have been
installed at Kaufmann for many years, the business administration
now recognised the necessity to invest in increasingly higher de -
manded perfect binding. Added to that, the planning and produc -
tion times in the print finishing industry have been considerably
reduced in times of faster data network and permanently available
communication media. This also affects the medium-sized machine
lines frequently used at Kaufmann, ranging in the size from
200,000 to 250,000 pieces. »Today, the throughfeed times are
considerably faster. Our industrial-oriented production processes
provide us with a significant competitive edge«, Markus Kaufmann
describes the situation.
Further information concerning the subject can be found under:
www.druckhaus-kaufmann.de/produkte/buchbinderei
www.kolbus.de
www.hugobeck.de/druck.htm
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