Heidelberg takes pre-press automation to the next level

Print Solutions

Heidelberg is committed to the goal of fully automating the print production value chain so that printing becomes an autonomous process. Even though digitalisation more or less started with pre-press, further potential to make efficiency gains still exists.

The company is taking the automation of computer to plate (CTP) processing to the next level by launching the Compact Pallet Loader (CPL) and the Compact Bender, and by integrating them into a single CTP line.

In conjunction with the Suprasetter 106/A106 platesetter models, the CPL enables fully automatic loading of printing plates into the systems. It also has a small footprint. The CPL covers all Suprasetter performance classes right up to the top of the line model, which operates at a speed of 55 plates per hour.

Integration into the Prinect workflow means the CPL supplies the CTP system with printing plates fully autonomously, in line with the job structure.

At the end of the process, the new Compact Bender plate bending system concludes the fully automated processing of the offset plates. When combined with an optional barcode recognition function, the system makes it possible to supply the plates required for the printing process – pre-sorted according to printing press, job, and plate set – without any manual intervention whatsoever.

‘By systematically pushing ahead with the goal of achieving end to end automation in pre-press production, Heidelberg is emphasising its credentials as a full range supplier for the entire packaging, commercial, and label production process. Print shops can use the Compact Pallet Loader and the Compact Bender to cut operating and personnel costs and counter the skills shortage,’ said Dr David Schmedding, chief technology and sales officer.

The Compact Pallet Loader is integrated into the CTP system and takes up hardly any additional space. This system can image 1200 printing plates in the size range 650 x 750 to 1050 x 1200 millimetres in non stop operation, pallet by pallet. In conjunction with the Compact Bender, the entire plate production process – from platesetter loading to plate bending – becomes largely autonomous. What is more, Suprasetter 106/A106 models manufactured from 2017 onward can be retrofitted with a CPL.

With its Compact Pallet Loader, Heidelberg is plugging a gap in computer to plate technology. In the basic configuration, the Suprasetter 106/A106 is automatically loaded with plates using the Dual Cassette Loader, which has a capacity of one hundred plates per cassette. At the opposite end of the scale is the Auto Pallet Loader (APL), which has a capacity of 1500 printing plates with a uniform plate format.

All Heidelberg solutions ensure fully automated, contact free plate handling with minimal personnel requirements. They also offer excellent flexibility in terms of formats and production volumes. Modules can be scaled to meet the relevant requirements and can also be combined.

One pilot user of the new Compact Pallet Loader is Druckstudio GmbH in Düsseldorf, which produces high quality commercial and packaging products for well known customers from the automotive, fashion, cosmetics, energy, advertising, and luxury goods industries. It also focuses on exceptionally sustainable and resource friendly production.

The company commissioned the CPL a few weeks ago, along with a new Suprasetter 106 and a Speedmaster XL 106-8-P. This eight colour press joins an existing Speedmaster XL 106-5+L. The increased plate processing requirements led to the decision to equip the Suprasetter 106 with the Compact Pallet Loader.

Werner Drechsler, founder and managing partner, commented: ‘The Compact Pallet Loader, together with a new bending and sorting line, is ensuring production runs smoothly. Work such as filling plate cassettes by hand and bending imaged printing plates previously took a great deal of time. Thanks to automation, we can now make these processes much more efficient and boost our productivity big time.’

In April 2024, Druckstudio GmbH also entrusted Heidelberg with the management of its consumables warehouse, using the company’s Vendor Managed Inventory (VMI) system. Here, Heidelberg automatically supplies new consumables as soon as the system detects that a minimum inventory level has been reached for a particular item.