Tecnau’s high-tech products work in synergy with the green economy

In recent years, increasing investments have been made in new digital printing and finishing technologies, mainly aimed at improving efficiency and increasing productivity. However, a renewed attention and sensitivity towards environmental sustainability issues is evident in all the phases of the manufacturing process, ranging from the choice of technologies to be selected for production, to electrical consumption, methods of providing technical support remotely and reducing paper waste.

The new solutions brought to the market by Tecnau show interesting implications in these areas that can be classified into four macro-categories: Flexible and automated Print On Demand (POD) systems for streamlining production, Implementation of advanced IoT (Internet of Things) technologies. Reduction of energy consumption. Development of intelligent interfaces with printing systems.

1. Flexible and automated print on demand (POD) systems for streamlining production

The rationalisation of production was driven by the progressive reduction in the number of copies produced for each order and by an exponential increase in the need for customisation. The process is leading printers to review both the manufacturing methods themselves and the entire organisational structure, with the need to look for solutions that can ensure scalability and a broad scope of applications.

Tecnau has long been moving in this direction to create solutions that allow it to manufacture batches of short runs or even single copies with highly automated and flexible systems, along with quick or “on the fly” format changes to reduce downtime and possible waste caused by starting & stopping of the line. These elements are necessary to implement a Print on Demand production flow that is based on the production of the batches actually sold and on the drastic reduction of inventories and unsold goods.

Tecnau’s Libra solutions for the publishing sector are the real workhorse of this production concept as they offer the possibility to produce completely different books in single copies at the same costs of larger runs. The absence of makeready times, on-the-fly format changes and the integration of all system components from roll unwinding to book binding and three-knife trimming, allow printers to produce only the quantities actually needed based on the quantities already sold.

(2) Implementation of advanced IoT (Internet of Things) technologies

The introduction of increasingly intelligent automatic control systems makes possible to meticulously supervise all phases of production, and to facilitate the maintenance and technical support activities required on any production line. Through the platform it is possible to remotely support installed lines all over the world, as well as to collect info on and analyze possible critical points to optimize technical assistance. Reducing travel of service personnel as well as ensuring a reduction in maintenance costs and intervention times produces a benefit to the community through the reduction of emissions.

(3) Reduction of energy consumption

During the product design process, Tecnau’s engineers focus on bringing benefits to users not only in terms of performance, but also in terms of consumption and savings. To this end, Tecnau is carrying out a project for the implementation of best practices that allow reduction of energy requirements of its machines through better management of motors and drives and total optimisation of the systems. The choice of materials and components used must certainly guarantee the stability and durability of the machinery over time, while reducing parts consumption in the long term.

(4) Development of intelligent interfaces with printing systems

Finishing lines are closely linked to printing systems and Tecnau has always maintained partnerships with all manufacturers of digital printers to improve the interfacing and provide customers with complete and integrated solutions. Tecnau has a particular focus on reducing waste as much as possible and improving the handling of white paper generated by continuous feed inkjet printers, especially during start/stop and application changeover. It is along these lines that Tecnau has introduced an automatic roll change system (Splicer u40) that not only increases productivity thanks to an elimination of roll change times, but also generates a continuous workflow, drastically reducing the white paper waste generated by the printer. Paper is a major component of total production costs; and waste, in addition to its economic impact, creates problems in plant management and disposal.

The details are in the INDONESIA PRINT MEDIA magazine, edition 88 May / June 2019

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