The GigaLynx is a further development of the SignaLynx, the original artificial vision system entirely developed by Meccanotecnica. Its purpose is to check the correct signature sequence on the gathering machines made by Meccanotecnica. In addition, it is installed on the Aster brand of book sewers, the UNIVERSE SEWING machine for digitally printed books and can be retrofitted to many different kinds of bookbinding machines.

Depending on its location, the system checks the correct sequence of signatures in different ways such as picture comparison (as it happens within the gathering lines and sewer feeders) or bar code readings, as it is carried out on the sewer transport saddles before their sewing and on the digitally printed sheet feeder into the UNIVERSE SEWING machine.

The maximum control level of the production process is guaranteed by the continuous monitoring of the product during the gathering and sewing steps. The real-time supervision reduces the amount of machine interruptions due to the presence of wrong signatures.

The GigaLynx is at the forefront of the multifunction quality control systems for the bookbinding industry. Its strength comes from the camera GIGABIT ETHERNET interface. It features high versatility and reliability and benefits from the reduced size of the camera which significantly helps during its installation.

The reading head - made of digital camera with CCD sensor - is mounted on each of the gathering machine pockets.

The pictures are sent to an Analyzer, the PC based image processing unit and core of the control system.

The Analyzer processes images from up to eight cameras at the same time.

The reliability of the operating system, Windows XP Embedded, together with the powerful calculation capacity of the processor, an Intel® Core 2 Duo, and the integrated GIGABIT ETHERNET switch make this system particularly reliable and versatile.

Each Analyzer connects to the 15” touch screen PC that serves as the user interface.

 The algorithm that is at the core of the GigaLynx system is able to adequately filter out the problems that generally affect the signatures during the normal binding process (i.e. machine acceleration, slight rotation, folding imperfections, and paper creases).

In the UNIVERSE SEWING machine, during the feeding of digitally printed sheets, the GigaLynx reads the bar code printed on the sheets and determines the proper machine programming. In other words, the GigaLynx is able to program the machine “on the fly” by using the job information included in the bar code.

Additionally, in the Universe Sewing, the GigaLynx bar code reading feature allows for the control of the signature feeder as well. In this way, the machine can automatically insert the folded signature in a predetermined spot within the folded & collated sheet flow.

Checking Barcodes

Printing bar codes on signatures and sheets allows for the highest degree of control over the gathering sequence. The GigaLynx works with the most common bar code specifications in the bindery: 2/5 interleaved and Code39. The position, size, and composition of the bar code must follow the specifications set by MECCANOTECNICA.

The “Book on Demand” by Meccanotecnica

The Book on Demand is the answer for those publishers and authors interested in producing “on demand” short runs of a “content” starting from its digital format.

Printing becomes a highly customized process and the author freely decides the technical requirements of the publication, without giving up the finishing quality within a short delivery time.

Since 1998 Meccanotecnica met this need and at that time launched the KRISTEC book sewing machine which collates, folds and sews single sheets coming from a sheet fed digital press.

Furthermore, the LEGOR-ASTER system which was launched by Meccanotecnica in 2000 produces book blocks while working in line with a web press; the machine takes the signatures just after the folding unit, squeezes and thread sews them.

Today, Meccanotecnica has developed the UNIVERSE DIGITALINE series, i.e. a new, more complete range of machines which produce a completely finished book starting from digitally printed single sheets, through four steps as thread sewing, pressing & endpapering, binding and trimming.

Customers have the option to buy the entire line or individual machines as the “UNIVERSE SEWING” or the “UNIVERSE BINDING” in their stand-alone configuration.

The UNIVERSE DIGITALINE series is the optimal solution not only for publishing products as yearbooks, photo albums, event commemoration books etc but also for short runs as minor author novels, catalogues and single encyclopedia volume reprints.

The book finishing line UNIVERSE DIGITALINE has four in-line units that finish a book starting from single sheets coming from digital printing.

The four units can be present singularly or in any combination allowing for maximum flexibility.

Just to give an example, the pressing, end papering & back gluing unit UNIVERSE INLINE can be placed immediately downstream from the UNIVERSE SEWING book sewer.

UNIVERSE SEWING

The sewing machine has the unique advantage to be modular, which means manufactured based on customer requirements.

The thread sewing unit comes from the famous Aster technology.

The originality of this machine lies in the simultaneous feeding of single sheets (which are previously folded and collated together to make a signature) and “offset” signatures that are directly fed onto the transport saddle.

Signatures can be manually fed on the saddle as well.

This combined feeding allows the mixing of standard contents with other personalized up to producing books all different each other.

A sheet sequence control system based on bar code reader surveys the operation and allows the machine autoprogramming, which gives a significant time saving and error free operation.

UNIVERSE INLINE

This unit works in line with the UNIVERSE SEWING from which it takes the book blocks and features a pressing station for both the book spine and the entire book block followed by an endpapering station.

For the last step the machine features the back gluing/lining stations; in case of soft cover binding, the UNIVERSE INLINE features a soft cover feeder and a hot melt back gluing station; in case of book to be further cased in, a lining station is fitted on the unit.

UNIVERSE BINDING

This six clamp perfect binding unit has been designed for high production rate and can be fed either in line from the UNIVERSE SEWING or manually with single sheet/signature piles.

The UNIVERSE BINDING looks like “oval” shaped standard binders and automatically adjusts in a very short time in case of similar jobs.

The machine optionally features a two motor milling station and hot melt or PUR back gluing station working through the same injection device.

Depending on finishing solution, feeding of soft covers or lining takes place in the last station of this unit.

UNIVERSE TRIMMING

This machine ends the book finishing within the UNIVERSE DIGITALINE through the standard, single pass three- knife trimming technology. The machine is straight fed for in line operation and features a high range of cutting tables together with a toolless changeover and extremely short preparation time.

The UNIPLEX is Meccanotecnica’s smallest line for gathering and sewing. It is ideally suited to production of sewn books composed of up to twelve signatures such as diaries, children's books and art catalogues.

The Uniplex line is a combination of an MX gathering machine and an Aster sewing machine. The gathering machine can have six, nine or twelve loading stations. The sewing machine can be an Aster 220C, an Aster 220SA, an asterPRO or an asterTOP.

Thanks to the short distance between the loading and unloading stations, the Uniplex line can be operated by just one person. Unlike the other Meccanotecnica lines, the Uniplex line has a fixed configuration.

Compared to production with freestanding machines, the Uniplex line offers the following advantages:

- No intermediate handling,

- storage and transport of gathered signatures

- Less personnel required

- Better organization of the production process

Depending on the number of stations, the MX gathering machine can be equipped with one or two colour touch-screen monitors. If the sewing machine stops, the operator can read the cause of the stop from a monitor and promptly intervene where needed.

The gathering machine features sequential start-up and emptying. Its speed automatically varies according to the speed of the sewing machine.

The three knife trimmer UNIVERSE TRIMMING does complete the UNIVERSE DIGITALINE program making the three side trimming of sewn or bound books; it can work either in line with the perfect binder UNIVERSE BINDING, thanks to a straight infeed conveyor equipped with a timed gate, or in a near line configuration.

Tried-and-tested mechanical systems with modern electronics make a machine that is very easy to operate and ready to deliver best quality products.

The machine features an automatic alignment device in the cutting station; standard supply does include a set of 15 cutting tables and correspondent pressing plates with the most common formats; on demand additional 12 sets can be supplied; cutting blades/knives can be standard or fine-grained hard metal as well.

The machine operates through a Siemens PC with a 15” touch screen display;

Key features are:

_ Choice of production mode

_ Format memory

_ Operator guided changes of the production mode

_ Automatic format settings

_ Automatic lock of the side knife adjustment and the pressing block

_ Operating instructions

_ Fine adjustments via +/– keys during running production

_ Product counter (job, shift and start/stop counter)

_ Indication of machine and material flow malfunctions

_ Operator guided malfunction elimination

_ Automated data management

_ Remote diagnostics

The changeover is automatic and toolless (besides pressing plates, which take less than 2 minutes to be changed); in order to trim books with similar thicknesses, adjustments during running production are allowed without changeover.

As for trim waste extraction and collection, the machines can be connected to a centralized system through a flexible pipe.

asterPRO. The target: EXCELLENCE.

This is what professionals are firmly keeping in mind and this has been the goal while designing the new unit. asterPRO incorporates all the cutting-edge technology introduced by MECCANOTECNICA for automatic book sewing.

MECCANOTECNICA launches into the market its most complete machine, its flagship unit. The perfect balance between automation and precision, speed and reliability. The ideal solution for all production needs.

asterPRO offers the new size of 440mm and 520mm (asterPRO/52), with speed up to 200 cycles/min for both versions. A full option unit - from the new active thread cutter and new conic punch needles to the new accelerator speed adjustment for each signature - meaning that the signature handling is customized as never before in order to get a perfectly sewn book block.

aster TOP. The target: SPEED.

asterTOP has shattered any previous speed record with its extremely high working speed. It is the ideal solution when top output is a “must”. Perfect for high performance gathering and sewing lines linked to a back-gluing or finishing lines.

asterTOP features three new cam boxes: two for the sewing and one for the feeder. These devices minimize vibrations and maintenance despite high output speed.

The secret of this model is increasing the speed by lowering paper stress. This has been achieved thanks to a new driving system, a new feeder squaring station and particularly by lowering the feeder speed and reducing the head register transfer.

The UNIVERSE BINDING is both a perfect binder and a book back gluer designed for short runs and digital printing. It has the elongated shape typical of high speed binders, features six clamps and “step” drive.

It was developed by marrying the simplicity and small footprint of on-demand binders with the strength, quality and versatility of high speed varieties.

When running books of similar kind but different sizes, the set up is fully automated. That includes all the clamps and various stations, with the exception of the tape cutter.

The UNIVERSE BINDING glues soft covers or gauze on sewn book block or signatures or loose sheets. The gluing can be traditional or employing specific solutions such as Otabind and Swiss Brochure.

The basic UNIVERSE BINDING includes:

- Infeed station.

- 3-channel, single application gun for book spine

- Two guns for side gluing

- Pressing station for the cover or the tape.

- Delivery station.

To the basic machine is added either a cover feeder or a tape feeder or both.

The infeed and delivery conveyors are options that can be configured according to the Customer specifications.

In the standard version, basic EVA hotmelt, there is a single pre-melter for both back and side gluing but separate glue tanks for each application. The pre-melter is detached from the machine and can be re-filled while the machine is running.

The optional PUR applicator comes with a dedicated system that accepts 20-kilo canisters and a fuser for the cleaning solution.

There are two ways to place the book blocks in the clamps: with an automatic system, available for sewn blocks only, or by hand, for loose sheets or signatures. In the first case, an optional conveyor can help speed up the loading. The same conveyor can be connected to the delivery of a sewing line or the UNIVERSE SEWING unit creating an automated production system. With the manual loader, a photoelectric barrier insures the safety.

The UNIVERSE BINDING also offers also an optional two-motors spine preparation unit (a.k.a. Milling station). The first 7.5 kW motor removes between three and four millimeters of paper from the spine. The second one (4.0kW) evens out the spine, notches it for accurate glue penetration and brushes of the dust particles.

An optional dust removal and collection system is available.

The Cover Feeder, drum style, includes four scoring wheel that are adjusted automatically during the setup. It is possible to add two more scoring wheels for covers with flaps but their position is adjusted manually.

In order to shape the spine correctly, the height of both lining and pressing stations can be fine tuned.

The book blocks are delivered spine-down from the side of the machine. They can be sent directly into the optional UNIVERSE TRIMMING three-knife trimmer.

The user interface is a 15” touch-screen panel through which all aspects of the production cycle can be controlled (sizes, temperatures, settings, etc.).