From prototype to production

16 September 2008



New eltromat system proved in practice at Drescher Print Solutions


A successful pilot installation of the prototype of eltromat’s revicon4 PrintQualitySystem at Drescher Print Solutions, in Rutesheim, Germany, is said to have given “sustainable proof of its series production readiness with outstanding results and set-up time savings of nearly 70 per cent”.

Part of eltromat’s integral range, the revicon4 combines the register and vision modules, and has been developed especially for applications where register control and web inspection “are indispensable for the production of high class printed products”.

Eltromat claims its new generation of integrated control systems for register, print and colour offers a high level of efficiency for web-fed printing, with various function modules that can be combined into customised configurations. Features include a camera based register control system, web-cylinder-measurement, mini register marks, absolute measurement of the front to back side, digital CCD cameras for the web inspection with optical zoom, and special flashes as well as a TFT touchscreen with CIP3/CIP4 thumbnail.

With the commissioning of the revicon4, which was retrofitted to an 8-colour Giebeler press (manufactured in 1990), taken over in 2006 from the French parent company Eppe Groupe, Drescher was able to increase the productivity of the second-hand machine considerably, and improve set-up times and quality standards significantly.

Drescher provides a full service for corporate communication, ranging from business print organisation to document management. In combination with its parent company Eppe, it is represented in most European countries.

The plant in Rutesheim, with more than 300 employees, specialises in business print and finishing. Sheet-fed and continuous printing of business forms, multi-part form sets and other print products is undertaken for banks, building societies and insurance companies, as well as for many large concerns in the automobile and branded goods industries.

The range of production spans from individual laser print and multi-part form sets in the millions to 14-fold application forms in short runs of just a few hundred copies. For the continuous print, Drescher presently uses offset presses from Drent, Muller Martini and Giebeler, with configurations of between four and 10 printing units.

Frank Pöllet, division manager responsible for narrow web production, comments: “In view of the high demands of our customers and the increasing material prices, we always aim to optimise set-up times and waste on our production lines, as well as the quality of our products. We have co-operated with eltromat since the ‘eighties and already have several generations of its register control, colour control and web inspection systems in use. In 2000, we installed the first PrintQuality complete system - an offcon2 - on a 10-colour Muller-Martini Concept NT press.

“Based on our very positive experiences with eltromat, there was no question about using its equipment on the 8-colour Giebeler press we acquired in 2006. It had originally been a mailing machine and initially ran for one year without any additional control systems. But after experiencing quality inconsistencies and control problems, we agreed to install the prototype of the revicon4 PrintQualitySystem.”

He continues: “This decision proved to be a complete success, because the system turned out to be a customised concept for our production demands. Since its installation in autumn 2007, all problems are under control and the machine’s set-up time and waste levels have been reduced to almost a third.

“This is the result of full co-operation between eltromat’s experts and our machine operators. During the commissioning phase, improvement proposals were immediately implemented. Register accuracy, set-up times and quality control have been optimised with the register and vision function modules, so the machine has been adapted to our productivity ideas and to the high quality demands of our customers.”

He concludes: “The new generation of eltromat integrated control systems is characterised by high precision, ease of use and reliability. The results before and after the installation of the revicon4 are poles apart. We are very satisfied with the performance and, moreover, we have still the option to extend the system with the colour module, to upgrade it with a colour control to a complete offcon4 system, in case of need.“


Frank Poellet (left) and eltromat sales manager Joerg Friedrich with the Giebeler press and PrintQualitySystem PrintQualitySystem The control console equipped with a TFT touchscreen offers operators high ease of use Touchscreen Related Articles
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