1. The Need for Digital Finishing
Paul Williams
Morgana Systems Ltd

2. Who Are We? Privately Owned UK Company Founded in 1977
Based in Milton Keynes
80 km North of London, UK
Originally formed as a Sales and Service company
Started manufacturing and exporting in 1984
First products UFO Folder and FSN Numbering Machine
Still in range today
circa 100 employees, Sales, Service, R&D and Production

3. Manufacturing Facility

4. What Do We Do? Design and build finishing machines
Primarily for the Digital Printing Segment
Distribute products for other manufacturers
If they offer exclusivity and suit the digital market
Sell and service direct in the UK
Through distributors and dealers in other markets.
Work with most of the Digital Engine manufacturers and Suppliers
Identify niche markets
React quickly, solve printers’ problems

5. What Problems?
Creasing versus Scoring

6. Creasing versus Scoring
Litho ink soaks into the stock
Scoring wheel will “cut” into the surface
but when folded the colour will be seen.
Job looks OK!
Digital print fuses to the surface
Scoring wheel will “cut” through the toner
and when folded white stock will be seen.
Job looks terrible!

7. How do we Solve Problems?
New Technology
Matrix Crease and Rule
6 tonnes of pressure applied
Fibres are compressed and not cut
Crease even across the sheet
Can fold in either direction
Lifetime Warranty on Matrix

8. Why Finishing? Finishing has always been the
“Cinderella” of the Printing Industry!
Investment in Pre-Press (DTP)
Then in CtP, then in Automatic Presses
Now in Digital Print Engines
Offering excellent quality
Getting faster
Becoming less expensive

9. Why Invest in Finishing?
Finally it is the turn for investment in Finishing!
The print market has vast over capacity
Pricing is under extreme pressure
Print quality is becoming generic
Customers expect quality in everything
Service levels are “expected” and are less of a benefit
A 2 day turn-around is no longer good enough

10. Why Invest in Finishing?
The question being asked is:-
“If I can’t differentiate through quality and service
and if prices are in decline how do I make money?”
The answer is:-
“By becoming a total solution provider for your customer”

11. What is a Total Solution?
From “data to document”
Customers don’t want a stack of printed sheets
They want finished (completed) documents
Booklets, brochures, bound reports, manuals, leaflets etc

12. What is a Total Solution?
The more you do for your customer the less they will worry about the cost of it!
Data management, design, creation, printing, finishing, mailing
Total Fulfilment
Remove their “headaches”
Offer a “Data to Document” service

13. Why Digital Finishing?
So if we agree that we need to supply finished documents......
Why can’t I use my conventional finishing equipment?
Set-up times
Cost (purchase price and hourly)
Waste
Paper handling characteristics

14. Why can’t I use what I’ve got?
Disruption!
Would you set up a stitch-liner to produce
30 x 16pp page books?
The waste would be more than the job!
The time would be longer than the print run
What damage may be done to the print?

15. Why can’t I use what I’ve got?
Disruption!
Would you stop the Polar guillotine to cut 250 business cards?
Average run 13 sheets 18 cuts
How long would it take?
What effect on other work?

16. Why can’t I use what I’ve got?
Disruption!
Would you stop the Stahl folder to fold 50 laminated menus?
How long would the set-up be?
What would the waste be?
What damage would be caused to the digital print?
Would the print crack?

17. Can I Use my Existing Equipment?
Yes...but only if you will accept
Long set-up times
High waste as a percentage of the total job
Damaged print due to mechanical handling
Unnecessary cost tying up large equipment for small runs
So really the answer is No!

18. What “Digital Finishing” is Available?
Creasing...(not scoring)
designed to stop cracking
Folders
designed not to mark the printed sheet
Booklet Makers
designed to feed multiple weights of stock
and to crease (cover, centre spread & individual sheets)

19. What “Digital Finishing” is Available
Creaser/Folders
will multiple crease and fold in one pass
one crease and fold for greeting card market
Perfect Binders
using PUR glue...needed to hold digital print
UV Coaters
designed to protect and enhance digital print

20. Online versus Nearline
Operations that produce the same product everyday
Financial – Educational – Governmental
Those who do not require flexibility
The system is only as fast as its slowest component
Nearline
Digital Engines run at optimum speed
Flexibility of production & finishing techniques
Still have production if failure occurs

21. Digital Finishing Products
Wide range available
Many suppliers offer some digital products:
Duplo – KAS – Uchida – Nagel – Graphic Wizard to name but a few.
but only one offers everything you will ever need!
Prices range from approx €500 to €70,000+

22. Table Top Creasers
Electric
Hand Fed, Computerised
Manual

23. Automatic Creasers
AutoCreaser Pro 50
AutoCreaser Pro 33

24. Creasers All use matrix an blade method
All offer the same quality of crease
All will crease in either direction
€500 to €15,000

25. Folders
Fully Automatic Set-Up
Semi-automatic Set-Up
Major
DocuFold

26. Folders For pre-creased stocks Small footprint Easy to use
semi-automatic
fully automatic
Pre-set folds

27. Creaser Folders many have tried....few have succeeded DigiFold Pro
AutoFold Pro

28. Crease & Fold Technology
No marking of the sheets
“Flying Knife” patented Folding
DynaCrease patented “on the fly” Creasing
Very high speed
DigiFold sheets per hour

29. DynaCrease Technology
Help
9 creases on 9 sheets in 9 seconds!

30. Flying Knife Technology
Creasing Unit
Large non damaging Fold Rollers
Flying Knives
Stock is creased
Stock moves into fold unit
First knife pushes stock up to fold on crease 1
Second knife pushes stock to fold on crease 2
Folded document arrives on the conveyor

31. Unique Products
DigiFold Pro- Computerised high speed creasing and folding machine

32. Booklet Makers
DocuMaster. The Complete Finishing System

33. Booklet Maker Technology
Feeds multiple weights from one feeder
perfect for pre-collated sets
cover and inside stock
sonic doubles detection
creases cover and centre spread (or all)
variable data camera system
square-back option
perfect bound look with stitch security

34. UV Coater
Protect and Hold
Fully Automatic UV Coater

35. UV Coating Protects the print Enhances the image Easy to use
Scratching
Postal damage
Enhances the image
Gloss, matt, textured
Easy to use
Can prime as well
Environmentally friendly
Biodegradable
No plastics

36. PUR Binders
Easy to Use Environmentally Friendly PUR Binders

37. PUR Binding 4 x stronger than hot-melt Will hold digital print
Can bind into gutter or double page spreads
Easy to use
Limited waste
Ideal for short runs

38. Smart Screen Technology

39. Summary Yes, Morgana can! Is Digital Finishing Different?
Yes, as different as an iGen is from a GTO
Do I need specialist products?
Yes, if you want to be profitable and productive and offer a “total solution”
Can you recommend who can help me?
Yes, Morgana can!

40. Thank you very much again for inviting me and thanks for listening!