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MullerMartiniPanoramaWinter201313neededjust12minutesincalendarweek2513.96HoursNon-StopThemarkedriseinproductivitywasen-abledbymodernizingSKNsmachinery.PreviouslySKNusedveBilinersfromMullerMartiniatitsplantinEmden.Basseexplainsthatweonlytookintoaccountfourandahalfofthoseinthestatisticsbe-causeonewasinneedofrepair.Todaythefamilybusinesswhichwasfoundedin1861andisrunbyBasseinthefthgener-ationusesthreeBilinersandtheFlexLinerwhichwasrstunveiledbyMullerMartiniatdrupa2012.TheFlexLinerhastwoinsertfeederswithstreamfeederswhichensurehighproductivityandisusedaroundtheclockonthefourmostproduction-intensivedaysfromMondaytoThursday.Itistypicallyop-eratedatfullproductionspeedof30000copiesperhourincludingwithsuctionopeningTheproductstravelfromtheFlexLinerwhichaccordingtoBassescalculationac-countsforatleast50percentofthemarkedproductionincreaseviaaconveyortothehigh-performanceRobustocompensatingstackerandarethenstrapped.TheIdealMachineBassesearchedforthreeyearsfortheop-timalsolutionforinsertinginsertsintoin-serts.Sinceheknewaheadofthelastdru-pathatMullerMartinihadaninsertingmachineinthepipelinecorrespondingex-actlytohisrequirementshewaskeentovisittheMullerMartinistandinDsseldorf.HewassoimpressedbythedemosthatheTheFlexLinerinsertingsystemfromMullerMartiniwhichwasrstunveiledatdrupa2012increasesefciencyinthemailroomcreatesreliabilityintraditionalnewspaperproductionandoffersnewproductdesignpossibilities.TheFlexLinercanbeexpand-edinanynumberofwaysthankstoitsopensystemarchitecture.Ifproductionre-quirementschangeimmediateactioncanbetaken.TheFlexLinercanbeexpandedwithtwo-pieceorfour-piecemodulesuptoamaximumof30insertstations.Theinsertstationscanbefedmanuallyorusingstreamfeedersasrequired.Addi-tionalpossibilitiesarecreatedbyindividu-aladdressinginthedeliverytransporterandtheintegrationofalabelingsystemoracardgluer.EBasselaysouttheweeklyproductionlogsfrom2012and2013activatesthecal-culatoronhisiPhoneandtellsthePanora-mareporterpolitelybutrmlytotakenote.79PercentIncreaseIncalendarweek0712weproduced6019copiespermachinehourincludingchangeoverandrepairtimeincontinuousoperationusingveinsertingsystems.Incalendarweeks1612and1712theg-ureswere6137and4930respectively.Thatresultsinanaverageof5695copiespermachinehourforthosethreeweeksin2012.Andnowpaycloseattentionnowusingjustfourinsertingsystemswepro-duced11532copiespermachinehourincalendarweek251310523incalendarweek2713and8561incalendarweek3013.Thatresultsinanaverageof10205copiespermachinehourforthosethreeweeksin201379percentmorethaninthepreviousyear.ThatswhatIcallasig-nicantincreaseThatriseisalsoreectedinthenumberofmachineminutesneededper1000cop-ies.WhileSKNrequired17minutesfor1000productsincalendarweek0712itTheFlexLinerFacilitatesInnovativeInsertMarketingWithFlexFeedselectivemainproductfeedingcustomershaveentirelynewop-portunitiestosetthemselvesapartfromthecompetition.Withtheuseofuptothreefeedingpositionswhichcanbefedmanu-allyfromtheFlexiRollordirectlyfromthewebprintingpressinsertscanbeplacedasFlexAdsonthefrontorbackpagesofamainproductinadditiontonormalinsertproduction.ThankstosuchprominentpositioningeachFlexAdstandsoutfromthemassofinsertsandhasfargreateradvertisingim-pactthantraditionalinserts.Uptothreeprintproductscanbeprocessedsimulta-neouslyusingtheco-mailingprocedureenablingvarioustitlestobecombinedanddistributed.Thesystemalsocaterstocom-plexmailroomrequirementssuchaszon-ingregionalizationandtheincreasingva-rietyofinsertsandpreprintedsections.SKNprocessessome200millioninsertsannually.ScantheQRcodeabovetoseetheFlexLinerfromMullerMartiniliveinaction.