Hunkeler Control Platform The Hunkeler Control Platform represents a modular solution for planning, controlling and monitoring the entire production processes. The concept comprises the stages ‘Print Processor’, ‘Workflow Monitor’, ‘Site Manager’ and ‘Production Reporter’. Integration into third party workflow systems in terms of the JDF standard is guaranteed.

Production Reporter

With Production Reporter, production processes are constantly recorded as part of an automated process. These records on the one hand enable quality assessment and on the other hand continual process improvement. The recorded production data is optimally stored in an intelligently structured and optimized archive.

additional options:

Print Processor

Preparing print jobs in the preliminary stage, Print Processor creates the basic conditions for optimal processing in finishing (cutting, folding and mailing). This includes automatic positioning of the individual pages in accordance with the selected folding patterns with all auxiliary characters such as printer’s imprints, EAN codes, data matrices etc. besides PDF processing, Print Processor also supports additional workflow systems commonly used in the digital print environment such as AFP (Advanced Function Printing).

Workflow Monitor

The Workflow Monitor unites Web Inspection for a comprehensive quality assurance and tracking for completeness verification. In the Web Inspection system, a high-resolution camera records printed elements (text, art design, codes, lines, logos, halftone images etc.) across the entire paper web width and on all pages. A comparison of the stored reference file enables recognition of faulty printed images, thereby making it possible to exclude the appropriate copies from production.

Site Manager

The Site Manager is a server with a visualization system which optimally works across individual plants via a web interface. In this way, production processes can be tracked on different lines and even at several sites independently of time and location. By accessing a web portal, customers too have the option of tracking their order in real time and ascertaining its status. An interface allows reporting back production data from the Site Manager to any type of management information system.

Hunkeler Control Platform

The Hunkeler Control Platform represents a modular solution for planning, controlling and monitoring the entire production processes. The concept comprises the stages ‘Print Processor’, ‘Workflow Monitor’, ‘Site Manager’ and ‘Production Reporter’. Integration into third party workflow systems in terms of the JDF standard is guaranteed.

Site Manager

The Site Manager is a server with a visualization system which optimally works across individual plants via a web interface. In this way, production processes can be tracked on different lines and even at several sites independently of time and location. By accessing a web portal, customers too have the option of tracking their order in real time and ascertaining its status. An interface allows reporting back production data from the Site Manager to any type of management information system.

additional options:

Print Processor

Preparing print jobs in the preliminary stage, Print Processor creates the basic conditions for optimal processing in finishing (cutting, folding and mailing). This includes automatic s imprints, EAN codes, data matrices etc. besides PDF processing, Print Processor also supports additional workflow systems commonly used in the digital print environment such as AFP (Advanced Function Printing).

Workflow Monitor

The Workflow Monitor unites Web Inspection for a comprehensive quality assurance and tracking for completeness verification. In the Web Inspection system, a high-resolution camera records printed elements (text, art design, codes, lines, logos, halftone images etc.) across the entire paper web

Pre- or Post-coating on Demand

PC7 Primer/Coater Module
With its PC7 primer coater module, Hunkeler presents a world’s first. This innovative solution can be used for primer application (pre-coating) or varnishing (post-coating). The PC7 coating module undoubtedly gives inkjet technology an additional impetus as an interesting alternative to established printing processes.

Primer Solution
The primer function finds application in the conditioning of paper webs prior to entering the printing system. The spectrum of types of paper suited for inkjet processes is experiencing a practically unlimited expansion in that standard offset paper can also be used with inkjet printing systems. Correspondingly large are the savings which can be achieved in the logistics costs with the purchase and warehousing of paper.

Coater Solution
In post-coating applications, the PC7 primer coater module can be used for the full-surface protective varnishing of the paper web with a waterbased dispersion or UV varnish following the printing process. Depending on coating weight and varnish different dryers are necessary. Optimized paper conditioning means even humidity levels in the paper web and best antistatic characteristics. The duplex coating ensures a warp-free web and best running characteristics in the following finishing processes.

Advantages
– Primer application without an active dryer
– Lower consumption cost due to small quantity of varnish
– Easy cleaning with water
– Shortest set-up time
– fast and reliable cleaning process at the push of a button
– Easy change of different varnishes
– Improving of inkjet print quality
– Coating of any substrates for inkjet printing
– Duplex coating eliminates paper curl
– Waterbased varnish for specific printers
– Paper is rehumidified
– Static electricity elimination

Technical Data PC7 Primer/Coater Module
– Web (762 mm)
– Production speed: up to 250 m/min (820 fpm)
– Paper weight: 40 – 300 gsm
– Applied quantity: 0.5 – 4.5 gsm
– Viscosity: 12 – 18 s DIN4 cup
– Fluid reservoir: 25 L or 50 L

Depending on the intended use, the PC7 is integrated either before or after the digital printing process. Off-line configurations are also possible. Depending on the application and varnish an evacuation system my be required.

The Roll Solution

The modular Hunkeler roll to roll solution with different configurations for digital continuous feed printing systems. The efficiency of rewinding printed rolls for post-processing in any application in the transactional, direct mail, print on demand, or packaging segment and high speed roll unwinding into inserters and other finishing systems.

UW6 / UW7 Unwind Module

The dynamic unwind module from the latest POPP generation is especially suitable for flexible, high-performance use. Easy handling, thanks to automated dancer control system and user guide with touch panel, reduces setup time to a minimum. Rolls with diameters of up to 1370 mm can be loaded semi-automatically. A triple dancer guarantees optimal and precisely tensioned winding of the paper web and helps with the processing of light as well as heavy paper weights. The dancer weight is fully decoupled, this guarantees optimal feed, also on high-performance digital printers.

Intelligent Operation

The new user interface is available on both modules and can be positioned on either side of the module depending on paper

The Roll Solution

The modular Hunkeler roll to roll solution with different configurations for digital continuous feed printing systems. The efficiency of rewinding printed rolls for post-processing in any application in the transactional, direct mail, print on demand, or packaging segment and high speed roll unwinding into inserters and other finishing systems.

UW6 / UW7 Unwind Module

The dynamic unwind module from the latest POPP generation is especially suitable for flexible, high-performance use. Easy handling, thanks to automated dancer control system and user guide with touch panel, reduces setup time to a minimum. Rolls with diameters of up to 1370 mm can be loaded semi-automatically. A triple dancer guarantees optimal and precisely tensioned winding of the paper web and helps with the processing of light as well as heavy paper weights. The dancer weight is fully decoupled, this guarantees optimal feed, also on high-performance digital printers.

Intelligent Operation

The new user interface is available on both modules and can be positioned on either side of the module depending on paper

Continuous quality assurance
The Web Inspection System WI6 is providing continuous digital print quality assurance to customers. Using state-of-the-art digital camera technology to scan the full width of the web, the WI6 system captures high-resolution images of printed output for various types of quality and integrity analysis. The WI6 System enables to ensure a consistently high print quality for mass mailing and print on demand applications. Print and integrity problems are immediately detected which allows instant reprints and leads to minized waste and downtime.

Error-free documents and flawless production
The Web Inspection System helps to guarantee error-free documents. The integrity of printed variable data is permanently monitored. Bad products can automatically be diverted and missing documents reprinted. The Web Inspection System can read document identification marks which allows a fully automated operation without manual supervision or adjustments. A user-friendly interface enables the operator to define different job templates which are automatically selected by the Web Inspection System. The Web Inspection System is available in simplex or duplex configuration and can run from 1-up to 4-up productions without reconfiguration.

Open integration
The Hunkeler WI6 is available as inline version to Hunkeler Rewinder RW6, Folder-Stacker FS6 and Cutter CS6 (optionally with automatic diversion) or as a standalone unit to combine with a variety of finishing modules from different vendors. Integration with into inserter or digital printing system, as well as AFP spooling and reprinting are available as options.

Features (depending on software option)
• Print quality control
• Data integrity verification
• Automatic stop of line or alarm
• Automatic diversion of bad copies
• Interface to tracking system of inserters
• Automatic reprints
• Job templates for automated setup
• Supports pin-fed and pin-less paper
• Supports continuous form and cut-sheet
• Interface to production control system
• Archiving of inspection results
• Interface to printer controller
• CMC -7 MICR support
• Connection to next higher controller platform via HCP Site Manager (incl. multi-site support)
• Support for RFID applications

Technical Data Web Inspection WI6 / WI7
• Print: Simplex & Duplex
• Web width: 6.5” – 30”
• Speed: 10 – 200 m/min
• Cameras: (depending on the line configuration and the speed)
   - Standard resolution 2x4096 Pixel linear (Duplex)
   - High resolution 2x8192 Pixel linear (Duplex) 

Benefits
• Guaranteed print quality
• Guaranteed data integrity
• Streamlined production
• Reduced waste

Pre- or Post-coating on Demand

PC7 Primer/Coater Module
With its PC7 primer coater module, Hunkeler presents a world’s first. This innovative solution can be used for primer application (pre-coating) or varnishing (post-coating). The PC7 coating module undoubtedly gives inkjet technology an additional impetus as an interesting alternative to established printing processes.

Primer Solution
The primer function finds application in the conditioning of paper webs prior to entering the printing system. The spectrum of types of paper suited for inkjet processes is experiencing a practically unlimited expansion in that standard offset paper can also be used with inkjet printing systems. Correspondingly large are the savings which can be achieved in the logistics costs with the purchase and warehousing of paper.

Coater Solution
In post-coating applications, the PC7 primer coater module can be used for the full-surface protective varnishing of the paper web with a waterbased dispersion or UV varnish following the printing process. Depending on coating weight and varnish different dryers are necessary. Optimized paper conditioning means even humidity levels in the paper web and best antistatic characteristics. The duplex coating ensures a warp-free web and best running characteristics in the following finishing processes.

Advantages
– Primer application without an active dryer
– Lower consumption cost due to small quantity of varnish
– Easy cleaning with water
– Shortest set-up time
– fast and reliable cleaning process at the push of a button
– Easy change of different varnishes
– Improving of inkjet print quality
– Coating of any substrates for inkjet printing
– Duplex coating eliminates paper curl
– Waterbased varnish for specific printers
– Paper is rehumidified
– Static electricity elimination

Technical Data PC7 Primer/Coater Module
– Web (762 mm)
– Production speed: up to 250 m/min (820 fpm)
– Paper weight: 40 – 300 gsm
– Applied quantity: 0.5 – 4.5 gsm
– Viscosity: 12 – 18 s DIN4 cup
– Fluid reservoir: 25 L or 50 L

Depending on the intended use, the PC7 is integrated either before or after the digital printing process. Off-line configurations are also possible. Depending on the application and varnish an evacuation system my be required.

Pre- or Post-coating on Demand

PC7 Primer/Coater Module
With its PC7 primer coater module, Hunkeler presents a world’s first. This innovative solution can be used for primer application (pre-coating) or varnishing (post-coating). The PC7 coating module undoubtedly gives inkjet technology an additional impetus as an interesting alternative to established printing processes.

Primer Solution
The primer function finds application in the conditioning of paper webs prior to entering the printing system. The spectrum of types of paper suited for inkjet processes is experiencing a practically unlimited expansion in that standard offset paper can also be used with inkjet printing systems. Correspondingly large are the savings which can be achieved in the logistics costs with the purchase and warehousing of paper.

Coater Solution
In post-coating applications, the PC7 primer coater module can be used for the full-surface protective varnishing of the paper web with a waterbased dispersion or UV varnish following the printing process. Depending on coating weight and varnish different dryers are necessary. Optimized paper conditioning means even humidity levels in the paper web and best antistatic characteristics. The duplex coating ensures a warp-free web and best running characteristics in the following finishing processes.

Advantages
– Primer application without an active dryer
– Lower consumption cost due to small quantity of varnish
– Easy cleaning with water
– Shortest set-up time
– fast and reliable cleaning process at the push of a button
– Easy change of different varnishes
– Improving of inkjet print quality
– Coating of any substrates for inkjet printing
– Duplex coating eliminates paper curl
– Waterbased varnish for specific printers
– Paper is rehumidified
– Static electricity elimination

Technical Data PC7 Primer/Coater Module
– Web (762 mm)
– Production speed: up to 250 m/min (820 fpm)
– Paper weight: 40 – 300 gsm
– Applied quantity: 0.5 – 4.5 gsm
– Viscosity: 12 – 18 s DIN4 cup
– Fluid reservoir: 25 L or 50 L

Depending on the intended use, the PC7 is integrated either before or after the digital printing process. Off-line configurations are also possible. Depending on the application and varnish an evacuation system my be required.

POPP6 – Investment protection

Roll to stack solution

The modular Hunkeler roll to stack solution for sheeted stack output with digital continuous feed printing systems. Innovative non-stop stacker or large sheet stacker with single cut sheeter or variable chip-out rotary double cutter for full bleed products in the Transactional/Transpromotional and Print on Demand segments.

CS6 Cross- and length cutter 

The rotary cross cutter CS6 consistently produces clean, accurate cuts at exact angles, ensuring the highest levels of productivity and quality of output. In combination with the register control software, it also provides the precision essential to the finishing process. Setups, as well as adjustments are easily performed at the Line-PC and display panel. An intgrated diverter separates waste from the production output. If equipped with the new, individually driven edge trimmers, and up to three linear cutters, the production of 4-up forms is accomplished reliably and efficiently.

CS6-I «Single Cut»

This version of the CS6 is equipped with a single rotary cutter for the production of traditional single cut forms in the print-on-demand and transactional printing segments.

CS6-II «Double Cut» 

The flexible high performance solution for mailing applications. By means of two independent, dynamically controlled rotary cutters, full bleed products are produced swiftly and accurately.

Technical Data POPP6 Roll to Stack line
• Web – 20.5” (165 – 520 mm)
• Cut length Stack: 5.5” – 19” (135 – 482 mm) 

                            3.5” – 28” 1) (89 – 711 mm) 

                  Sheet: 8” – 62” (203 – 1575 mm)
• Variable chip-out: 1/8” – 2 3/4” (3.2 – 70 mm)
• Paper weight: 40 – 300 gsm
• Production speed: up to 500 ft/min (150 m/min)
• Applications: 1up – 4up with gutter cut
• Option: Pinless Merger

Additional modules:

SE6 Offset module 

All sheets are offset on-the-fly before passing them on to the stacker module. The unique separation unit enables true separated offset stacks in 1up, 2up, 3up and 4up mode. The stacks with horizontally offset book blocks facilitate the easy handling of stacks.

LS6 Stacker module 

In the stacker module LS6, all signatures or sheets are collected and continuously stacked to the desired

Continuous quality assurance
The Web Inspection System WI6 is providing continuous digital print quality assurance to customers. Using state-of-the-art digital camera technology to scan the full width of the web, the WI6 system captures high-resolution images of printed output for various types of quality and integrity analysis. The WI6 System enables to ensure a consistently high print quality for mass mailing and print on demand applications. Print and integrity problems are immediately detected which allows instant reprints and leads to minized waste and downtime.

Error-free documents and flawless production
The Web Inspection System helps to guarantee error-free documents. The integrity of printed variable data is permanently monitored. Bad products can automatically be diverted and missing documents reprinted. The Web Inspection System can read document identification marks which allows a fully automated operation without manual supervision or adjustments. A user-friendly interface enables the operator to define different job templates which are automatically selected by the Web Inspection System. The Web Inspection System is available in simplex or duplex configuration and can run from 1-up to 4-up productions without reconfiguration.

Open integration
The Hunkeler WI6 is available as inline version to Hunkeler Rewinder RW6, Folder-Stacker FS6 and Cutter CS6 (optionally with automatic diversion) or as a standalone unit to combine with a variety of finishing modules from different vendors. Integration with into inserter or digital printing system, as well as AFP spooling and reprinting are available as options.

Features (depending on software option)
• Print quality control
• Data integrity verification
• Automatic stop of line or alarm
• Automatic diversion of bad copies
• Interface to tracking system of inserters
• Automatic reprints
• Job templates for automated setup
• Supports pin-fed and pin-less paper
• Supports continuous form and cut-sheet
• Interface to production control system
• Archiving of inspection results
• Interface to printer controller
• CMC -7 MICR support
• Connection to next higher controller platform via HCP Site Manager (incl. multi-site support)
• Support for RFID applications

Technical Data Web Inspection WI6 / WI7
• Print: Simplex & Duplex
• Web width: 6.5” – 30”
• Speed: 10 – 200 m/min
• Cameras: (depending on the line configuration and the speed)
- Standard resolution 2x4096 Pixel linear (Duplex)
- High resolution 2x8192 Pixel linear (Duplex)

Benefits
• Guaranteed print quality
• Guaranteed data integrity
• Streamlined production
• Reduced waste

POPP6 – Investment protection

Roll to stack solution
The modular Hunkeler roll to stack solution for sheeted stack output with digital continuous feed printing systems. Innovative non-stop stacker or large sheet stacker with single cut sheeter or variable chip-out rotary double cutter for full bleed products in the Transactional/Transpromotional and Print on Demand segments.

CS6 Cross- and length cutter
The rotary cross cutter CS6 consistently produces clean, accurate cuts at exact angles, ensuring the highest levels of productivity and quality of output. In combination with the register control software, it also provides the precision essential to the finishing process. Setups, as well as adjustments are easily performed at the Line-PC and display panel. An intgrated diverter separates waste from the production output. If equipped with the new, individually driven edge trimmers, and up to three linear cutters, the production of 4-up forms is accomplished reliably and efficiently.

CS6-I «Single Cut»
This version of the CS6 is equipped with a single rotary cutter for the production of traditional single cut forms in the print-on-demand and transactional printing segments.

CS6-II «Double Cut»
The flexible high performance solution for mailing applications. By means of two independent, dynamically controlled rotary cutters, full bleed products are produced swiftly and accurately.

Technical Data POPP6 Roll to Stack line
• Web width            6.5” – 20.5” (165 – 520 mm)
• Cut length Stack:  5.5” – 19” (135 – 482 mm)
                             3.5” – 28” 1) (89 – 711 mm)
                   Sheet: 8” – 62” (203 – 1575 mm)
• Variable chip-out:  1/8” – 2 3/4” (3.2 – 70 mm)
• Paper weight:       40 – 300 gsm
• Production speed:  up to 500 ft/min (150 m/min)
• Applications:         1up – 4up with gutter cut
• Option:                 Pinless Merger PM6

Additional modules:

SE6 Offset module
All sheets are offset on-the-fly before passing them on to the stacker module. The unique separation unit enables true separated offset stacks in 1up, 2up, 3up and 4up mode. The stacks with horizontally offset book blocks facilitate the easy handling of stacks.

LS6 Stacker module
In the stacker module LS6, all signatures or sheets are collected and continuously stacked to the desired

FS6 – Perfect Stack Quality
The modular Hunkeler roll to fan-fold solution with optional vertical stacking systems and carts for efficient print and mailroom operation. Reliable inline high speed operation with digital continuous feed printing systems in a space saving package and many modular options such as forms processors, web inspection, stack turner, etc.

FS6 Folding Module
The continuous Folder Stacker FS6 achieves remarkable stack quality up to 220 m/min production speed. The continuous web is meticulously folded by a spiral folding system, and stored by a high capacity stacker in precise stacks of up to 1000 mm. These perfect, compact stacks are essential for smooth post processing. As an option, the new Line PC permits unlimited storage of various job data, offering automatic set up and make ready of previously stored job processing data by the touch of a button. Complete stacks exit the module without printer stop. The high degree of automation by way of electronic assistance for format changes brings about substantial reductions in set up times and considerable increases in productivity. This makes the FS6 an excellent investment for all segments requiring fan folding. The heavy duty folder has been designed for maximum availability and to be operator and service friendly. This enables one operator to control several lines simultaneously. State of the art servo, and web handling technology allows the same machine to be used in-line with the latest high speed printing systems – slack, or tight web – as well as off line, for instance in conjunction with a Hunkeler VARIWEB system.

Versatile High Speed Folder
• Shingle Belt Delivery
For the delivery of added value products such as forms with integrated labels or plasticized cards

• Stack Cart System
Stacking of up to 16’000 forms in 2-up operation. Easy unloading of stacks and transfer by stack carts to inserter area.

• High Capacity Stacker
The tightly folded, horizontal shingle stream is automatically brought into a vertical Stack Turning Module Application specific turning of stacks (A-Z or Z-A) for correct feeding into inserter. 

Technical Data FS6 Folder stacker
• Paper web – 20.5” (203 – 520 mm)
• Folding 70 gsm): 7” – 12” (178 – 305 mm)
                         *( > 70 gsm): 7” – 17” (178 – 431 mm)
• Paper weights: 56 – 160* gsm
• Speed: 3 – 720 ft/min (10 – 220 m/min) Stack height: up to 39.4“ (up to 1000 mm) 

DC7 Drum collator module
Within the drum collator, sheets processed by the cutting module are collated on a rotary drum. This innovative patent approach to sheet assembly works continuously, without printer stop regardless of the number of sheets to be collated. The unique rotary aspect of the module’s design results in precise and gentle handling of the product. Essential processing data regarding format, sections, and diversion of waste sheets is transferred directly from the cutting module. Set-up and adjustments are easily performed at the touch screen display panel. Optional gluing device for dot and line gluing with up to four glue nozzles.

The modular Hunkeler newspaper solution for the production of variable on demand tabloid and broadsheet newspapers offline or inline with digital continuous feed printing systems. Line or dot gluing option for collated tabloid newspaper, brochures or signatures.

Newspaper, brochure and signature production
This pioneering response to current industry challenges addresses a number of different issues, such as decreased circulation, reduced advertising volume, greater competition, and a need for increasingly timely news. The innovative concept underlying this technology allows the geographically independent production of up-to-date news- papers, digitally printed in the well known broadsheet format. Center stage to the solution is the drum collating module DC7. This module collates the duplex printed sheets of variable size. The papers leave the collating module as a electrostatic fixed stack. As an industry first, this solution offers publishers the opportunity to produce as few or as many newspapers, with as few or as many pages as locally pertinent, anywhere in the world. From any location, editors will modify, fine-tune, and revise data to make it completely relevant to specific markets before transmitting it via internet to the printing location. In addition, content is edited and advertising added promptly, even during the printing process, thanks to the digital print system’s dynamic layout capabilities. This technology is revolutionary in that it offers an entirely novel approach to newspaper production. During off-peak hours the system can be used, for the the production of brochures, book signatures or mailings. 

Technical Data

                              POPP6                     POPP7
                              (UW6-CS6-DC7)       (UW7-CS7-DC7)
Web width:              11” – 20.5”              11” – 26”
                              (279 – 520 mm)       (279 – 660 mm)
Cut length:               up to 31.9”              up to 31.9”
Paper weight:           40 – 120 gsm          40 – 120 gsm
Speed:                     up to 150 m/min     up to 130 m/min
                               (500 ft/min)            (360 ft/min)
Collating capacity:     2 – 24 Sheets          2 – 24 Sheets
Folding system:         2-12 Sheets dynamic production,
                               over 12 sheets static processing only
Example of productivity:1180 ex/h Broadsheet (cut length 24.8”)
                                   2270 ex/h Tabloid (cut length 12.99”)
                                   with printer speed 500 ft/min
                                   48 pages 

Modular book block solution
The modular book solution for the production of glued book blocks in-line or off-line for continuous digital printing systems up to a paper web width of 30“. Processing of 4, 6 or 8-page signatures with quick setups and format changes. The high- performance Cross Cutter CS6-HS and the new Double Star Wheel Delivery SD7 guarantee non-stop production at 200 m/min with over 450 output cycles per hour. In one stacking cycle, several book blocks are delivered, which for example amounts to 2,245 books per hour in A5 format on a book length of 192 pages. The system is characterized by modularity and flexibility coupled with simple and safe handling for further processing thanks to integrated book block gluing and perfectly flat book stacking. The book-on-demand line can be used as a flexible near-line solution or as an in-line system and is designed for the low to medium volume segment.

PF7 Double Plow Fold module
This module is designed for book signature production from paper webs of 10 to 30 inches (762 mm). The double folding unit permits production of signatures with 4, 2 times 4 (double production), 6 or 8 pages. Thanks to a simple changeover, setups can be accomplished very quickly.

SD7 Star Wheel Delivery  
The non-stop Stacker Module produces at a speed of up to 200 m/min and processes format lengths between 8 to 14 inches for pre-glued book blocks up to approximately 50 mm in thickness and stacking heights up to 120 mm. This makes transfer into a perfect binder very easy and guarantees safe handling.

Online JMF-Interface for JDF readiness
The system can be optimally controlled from a central control station and offers, via the JMF interface, the option of a JDF connection, provided that the connected systems are designed for such connections.

Technical data for modular book block solution
Roll diameter:            max. 50“ (1270 mm)
Web               up to 30“ (762 mm)
Production speed:       up to 656 ft/min (200 m/min) product-dependent
Paper weight:            50 – 150 gsm
                                for plow fold: 2x150 gsm
                                                    3x100 gsm
                                                    4x 80 gsm
Folds:                        1 to 2 plow folds (2 to 3 layers)
Format length:           8 – 14“ (203 – 355 mm)
Book block thickness: up to 50 mm
Stack           up to 120 mm
Productivity:              up to 450 delivery cycles per hour
     - for format 6x9“: 4140 book blocks with 96 pages
     - for format DINA4: 2420 book blocks with 96 pages  

Flexibility with a new laser process

Hunkeler presented an innovative, patented laser process for safety punching and perforation. The areas of applications include the production of checks, coupons and direct mail pieces where the dynamic stamping of distinct individual shapes for safety characteristics or any arbitrary dynamic perforation pattern is required. The laser module works with an until now unheard of speed of up to 150 meters per minute, in 1-up or 2-up mode and can be integrated into all Hunkeler configurations. The Hunkeler Laser HL6 has been developed in close cooperation with ElEn Laser Technologies and is based on their well-proven laser technology.

System consisting of:
– HL6 Hunkeler Laser Modul
– 1 Chiller per laserhead
– Exhausting system for paper waste and dust, filtering the air with carbon filters
– Air dryer for compressed air
– WI6 Web Inspection System

Use of the WI6 web inspection system from the Hunkeler Control Platform ensures the in-line monitoring of security punching and perforations.

Advantages
– Complex and dynamic perforations
– Cut outs with holding points or die cutting
– Dynamic text or graphic engraving (i.e. security features on checks)
– Flexible continuous operation at 150m/min
– Fully proven laser technology by ElEn Technologies
– Intelligent laser editor for easy job setup
– Direct marking from data matrix (read & perf)
– 64 different tools (pens with different perforation patterns)
– No brown edges
– Double protected laser area
– Automatic fire extinguishing
– Clean air due to active carbon filters
– Integrated into Hunkeler configurations

Technical Data Hunkeler Laser HL6
Web – 20.5” (178 – 520 mm)
Paper weight: 40 – 300 gsm
Speed:* up to 150 m/min (500 ft/min)
Electrical power: 12kW (3x400VAC) HL6-II
Laser type: CO2 Laser
Laser class: Class 1
Laser power: 350W
Laser dot size: 0.2 mm
Cooling: 1 Chiller per laserhead
Accuracy: ± 0.2 mm

Die Cut, Perforation and Cross Cut in a Single Module

Universal Module UM 520-W
Combining the work processes of die cut, perforation and cross cut with variable cut-out in a single module provides unparalleled flexibility in product design and cost-effective production.

From roll into a finished mailing in one run
Working from a roll and connecting the possibility of having almost no limitations in product design with the high productivity of the web finishing is leading to clear advantages compared with single sheet processing.

For individual end products
• Modular construction
• Can be extended with other units and modules at any time
• Free Processing input from stack to roll
• Most varied formats can be die-cut with a single magnetic die cutting cylinder
• Die cut, perforation and cross cut (with variable cut-out with a single module)
• Production speed of up to 150 m/min (depends on product)

Technical data Universal Module UM 520-W
Paper web  150 – 520 mm
Final formats:         4” – 34”
Paper weight:         60 – 160 gsm
Production speed:   max.150 m/min (dep. on product)
Variable cut out:     1/4” – 2”

Flexibility with a new laser process

Hunkeler presented an innovative, patented laser process for safety punching and perforation. The areas of applications include the production of checks, coupons and direct mail pieces where the dynamic stamping of distinct individual shapes for safety characteristics or any arbitrary dynamic perforation pattern is required. The laser module works with an until now unheard of speed of up to 150 meters per minute, in 1-up or 2-up mode and can be integrated into all Hunkeler configurations. The Hunkeler Laser HL6 has been developed in close cooperation with ElEn Laser Technologies and is based on their well-proven laser technology.

System consisting of:
– HL6 Hunkeler Laser Modul
– 1 Chiller per laserhead
– Exhausting system for paper waste and dust, filtering the air with carbon filters
– Air dryer for compressed air
– WI6 Web Inspection System

Use of the WI6 web inspection system from the Hunkeler Control Platform ensures the in-line monitoring of security punching and perforations.

Advantages
– Complex and dynamic perforations
– Cut outs with holding points or die cutting
– Dynamic text or graphic engraving (i.e. security features on checks)
– Flexible continuous operation at 150m/min
– Fully proven laser technology by ElEn Technologies
– Intelligent laser editor for easy job setup
– Direct marking from data matrix (read & perf)
– 64 different tools (pens with different perforation patterns)
– No brown edges
– Double protected laser area
– Automatic fire extinguishing
– Clean air due to active carbon filters
– Integrated into Hunkeler configurations

Technical Data Hunkeler Laser HL6
Web – 20.5” (178 – 520 mm)
Paper weight: 40 – 300 gsm
Speed:* up to 150 m/min (500 ft/min)
Electrical power: 12kW (3x400VAC) HL6-II
Laser type: CO2 Laser
Laser class: Class 1
Laser power: 350W
Laser dot size: 0.2 mm
Cooling: 1 Chiller per laserhead
Accuracy: ± 0.2 mm

* Depending on application 

Dynamic perforating and punching

Dynamic perforation and punch module DP6
Dynamic perforation and punching combined in a modular concept. In 2-up production this permits individual processing of the two web halves. Combined use of three different functions is possible in a single module (dynamic perforation in the longitudinal and transverse ">Technical Data DP6
- Paper web – 20.5” (165 – 520 mm)
- Format length: 5.5” – 62”
- Perforation distance:
         up to 100 m/min 2” with 1 cylinder
                                  1” with 2 cylinders in series
         up to 150 m/min 4” with 1 cylinder
                                  2” with 2 cylinders in series
- Paper weight: 40 – 200 gsm
- Speed: up to 150 m/min (500 ft/min)

Punching and perforating module PP6
The PP6 was designed for in line finishing of unprinted paper rolls (sprocket hole punching, longitudinal and transverse perforation, fold perforation, file hole punching, form punching etc.) with the typical application areas of transactional and transpromotion printing in data centres. Simple operation: The perforation cylinders can be changed by the operator and the other tools are maintained via cassettes. The active web cleaning and the evacuation of the confetti through the tools guarantee a clean and dust-free web. For the registration of the printer in pinless mode an optional print unit prints a top of form mark.

Technical Data PP6
- Paper web – 20.5” (165 – 520 mm)
- Folding perforation: 8” – 14” (static)
- Paper weight: 60 – 180 gsm
- Speed: up to 220 m/min* (730 ft/min)

The ultimative cutting system
The modular Hunkeler high speed roll to cut solution for sheeted output offline or inline with digital continuous feed printing systems. Optional slit-merge or plow folding with the variable chip-out rotary double cutter for full bleed products in the Direct Mail and POD markets. 

CS6 Cross- and length cutter
The rotary cross cutter CS6 consistently produces clean, accurate cuts at exact angles, ensuring the highest levels of productivity and quality of output. In combination with the register control software, it also provides the precision essential to the finishing process. Setups, as well as adjustments are easily performed at the display panel. The new Line-PC permits unlimited storage of various job data, offering automatic set up and make ready of previously stored job processing data by the touch of a button. An integrated diverter separates waste from the production output. If equipped with the new, individually driven edge trimmers, and up to three linear cutters, the production of 4-up forms is accomplished reliably and efficiently.

CS6-I «Single Cut»
This version of the CS6 is equipped with a single rotary cutter for the production of traditional single cut forms in the print-on-demand and transactional printing segments.

CS6-II «Double Cut»
The flexible high performance solution for mailing appli- cations. By means of two independent, dynamically controlled rotary cutters, full bleed products are produced swiftly and accurately.

Technical Data Cutter CS6-II
Web         6.5” – 20.5” (165 – 520 mm)
Cut length:           5.5” – 62” (135 – 1575 mm)
Variable chip-out: 1/8” – 2 3/4” (3.2 – 70 mm)
Paper weight:       40 – 300 gsm *
Production speed: up to 600 ft/min (180 m/min)
Applications:         1up – 4up with gutter cut
Option:                 - merger + plow folder
                            - dynamic cut lengths

High Reliability
Rotary scissor cut technology guarantees highest reliability and precise, consistently accurate cuts, creating minimal dust. Integrated carbide knifes allow for more than 30 Mio cuts between knifes changes. The CS6 offers a service friendly layout, accompanied by state-of-the-art drive technology and ergonomic design.

Flexibility
The CS6 proficiently cuts any sheeted products, from fullbleed forms to signatures, deriving its high level of flexibility from a wide variety of chip-out sizes and cut off lengths. Optional dynamic cut lengths. Undemanding operation by touch screen and Line-PC, programmed in a number of different languages, as well memory functions for machine set-up increase ease of operation and productivity.

Investment protection
By processing paper weights from 40 to 300 gsm, and operating at speeds of up to 600 ft/min, the CS6 fulfills tomorrow’s requirements of the market. The dynamic diversion of waste or blank sheets leads to an efficient downstream process that no longer requires manual intervention.

Modular concept
This allows for flexible customization to your specific requirements. The line, for instance, can be expanded either with a web-merger module WM6 or the combination module plow- folder/web-merger FM6 to create an universal high speed mailing system.

Pre- or Post-coating on Demand

PC7 Primer/Coater Module
With its PC7 primer coater module, Hunkeler presents a world’s first. This innovative solution can be used for primer application (pre-coating) or varnishing (post-coating). The PC7 coating module undoubtedly gives inkjet technology an additional impetus as an interesting alternative to established printing processes.

Primer Solution
The primer function finds application in the conditioning of paper webs prior to entering the printing system. The spectrum of types of paper suited for inkjet processes is experiencing a practically unlimited expansion in that standard offset paper can also be used with inkjet printing systems. Correspondingly large are the savings which can be achieved in the logistics costs with the purchase and warehousing of paper.

Coater Solution
In post-coating applications, the PC7 primer coater module can be used for the full-surface protective varnishing of the paper web with a waterbased dispersion or UV varnish following the printing process. Depending on coating weight and varnish different dryers are necessary. Optimized paper conditioning means even humidity levels in the paper web and best antistatic characteristics. The duplex coating ensures a warp-free web and best running characteristics in the following finishing processes.

Advantages
– Primer application without an active dryer
– Lower consumption cost due to small quantity of varnish
– Easy cleaning with water
– Shortest set-up time
– fast and reliable cleaning process at the push of a button
– Easy change of different varnishes
– Improving of inkjet print quality
– Coating of any substrates for inkjet printing
– Duplex coating eliminates paper curl
– Waterbased varnish for specific printers
– Paper is rehumidified
– Static electricity elimination

Technical Data PC7 Primer/Coater Module
– Web (762 mm)
– Production speed: up to 250 m/min (820 fpm)
– Paper weight: 40 – 300 gsm
– Applied quantity: 0.5 – 4.5 gsm
– Viscosity: 12 – 18 s DIN4 cup
– Fluid reservoir: 25 L or 50 L

Depending on the intended use, the PC7 is integrated either before or after the digital printing process. Off-line configurations are also possible. Depending on the application and varnish an evacuation system my be required.

Hunkeler Web Finishing allows the added value of print products to increase during the production of needs-oriented means of organization, communication and advertising. Combined with a subsequent or integrated digital print system, Web Finishing opens up entirely new possibilities in the paper-processing field.

Systems
Hunkeler develops and supplies modular Web Finishing Systems for the production of multifunctional forms and creative mailings. The modular configurations for needs-oriented system solutions, combined with state-of-the-art technology, guarantee the customer optimal flexibility in product design, even in the face of high productivity levels.

Solutions
We offer integrated Web Finishing solutions to meet your specific demands. The modular system configuration allows flexible setups to meet your exact requirements. Further customization is possible through the integration of third-party equipment, such as dryers and folding devices, into Hunkeler Web Finishing Systems.

Intelligent paper products
The Hunkeler Web Finishing Systems allow transponder inlays to be integrated into a document in the most varied forms. Whether as an integrated RFID label or integrated plastified card, documents with transponders simplify and control entire production supply chains or can be used for personal identification and access controls.

Variweb – All in one
• Modular construction
• Can be extended with other units and modules at any time
• Free Processing input from stack or roll
• Processing output in staple, roll or sheet
• Precise glue application
• Format independent (application, die cut, fan folding)
• Cut lengths can be set without changing gear wheels
• Patch position can also be changed during production
• Most varied formats can be die cut with a single ­magnetic die cut cylinder
• Folding Production speed of up to 150 m/min (depends on product)

The Roll Solution
The modular Hunkeler roll to roll solution with different configurations for digital continuous feed printing systems. The efficiency of rewinding printed rolls for post-processing in any application in the transactional, direct mail, print on demand, or packaging segment and high speed roll unwinding into inserters and other finishing systems.

UW6 / UW7 Unwind Module
The dynamic unwind module from the latest POPP generation is especially suitable for flexible, high-performance use. Easy handling, thanks to automated dancer control system and user guide with touch panel, reduces setup time to a minimum. Rolls with diameters of up to 1370 mm can be loaded semi-automatically. A triple dancer guarantees optimal and precisely tensioned winding of the paper web and helps with the processing of light as well as heavy paper weights. The dancer weight is fully decoupled, this guarantees optimal feed, also on high-performance digital printers.

Intelligent Operation
The new user interface is available on both modules and can be ">                                POPP6 (UW6)               POPP7 (UW7)
Max. roll diameter:    1370 mm (54”)             1370 mm (54”)
Web              6.5” – 20.5”                 6.5” – 30”
Speed:                     10 – 220 m/min            10 – 220 m/min
Paper weights:          40 – 180* gsm              40 – 300 gsm
Max. roll weight:       800 Kg                          800 Kg

*Optional POPP6 Heavy paper kit: 40 – 300 gsm