Duplo Unveils a Range Of New Products and Flexibile Finishing Solutions

DÜSSELDORF, GERMANY— 29/05/2008—On the first day of drupa, Duplo is unveiling further new additional products on its stand: the fully automatic and user-friendly Ultra 205A UV Coater; the DuWrap, a polywrapping unit for the mail fulfilment market and a new friction fed collating range including the DFC-100 and DFC-120 Mini Collator.

Visitors have the opportunity to experience technology previews as well as a range of other new products and innovative modular finishing configurations which will allow printers to introduce sophisticated value-added finishing processes to their customer offerings.

In addition to the UV Coater and DuWrap product, visitors to the exhibition will also see for the first time Duplo’s unique DC-645 Production Colour Finisher with a new knife folder, adding further application possibilities to the already versatile slit, cut and crease machine. drupa will also see the first showing of the intelligent DSF-5000 high speed dynamic document sheet feeder; Duplo’s new PUR DuBinder as well as the launch of the new mid-range bookletmaker DBM-350/T. drupa is also the venue for the first European showing of the UJ-500AS anti-static ionised jogger designed to improve sheet feeding.

Akio Kaneko, Manager, International Sales Group at Duplo Corporation comments: “Duplo has been taking the industry lead in ensuring that print providers understand the significance of effective, flexible finishing within the production process and the benefits it can bring to their business.

Introducing value-added finishing processes to their customer offering will help them to differentiate from their competitors, increase margins on individual jobs, establish profitable relationships as well as move into new areas and thus grow their overall business potential.”

He continues: “Following valuable feedback from our customers worldwide, we’ve been extremely busy developing new advanced, cost-effective finishing solutions that produce high quality, multiple applications to suit the requirements of traditional offset, digital or hybrid printing houses. There is no better platform than drupa to showcase our new versatile solutions, demonstrating our commitment to a very dynamic industry.”

New Technology Previews

DuWrap Polywrapping Unit

At drupa 2008, the Digital System 5000’s capability is being further extended by adding a mail fulfilment function to the bookletmaking process and as such further adding value to a customer’s business. The Duplo DuWrap, a polywrapping unit, is connected to the Digital System 5000 to demonstrate the complete production of a booklet and mailing solution in one system.

Two applications are being on the Duplo stand: A bar-code driven personalised investment report and an investment booklet combined with a variable data single address. Both applications will run through the DSF-2000, SCC and DBM-500/T bookletmaking line and into the DuWrap where a transparent polywrap film will envelop them ready for mailing. Job tracking and auditing will be performed by a camera-based vision system from Böwe Bell & Howell.

DC-645 Production Colour Finisher with New Conveyor/Folder/Stacker

For the first time, Duplo is adding a knife folding option to the versatile DC-645 slitter, cutter, creaser, thus hugely extending the online capability of the production colour finisher. By incorporating folding into the single system operation, printers can now fully finish different applications such as greeting cards, folded ‘tent’ business cards, brochures, leaflets and many more.

The knife folder incorporates two knife folds making it also ideal for parallel fold applications such as letter folds. With a speed of up to 50 sheets per minute, the new folder fully matches the capabilities of the DC-645 and can also be by-passed for no-fold applications from the DC-645.

The finished documents are then collected in a 400mm capacity stacker specifically designed to neatly stack and retain even heavier jobs such as folded card stock.

At drupa, Duplo is presenting the DC-645 in a straight conveyor/folder/stacker configuration, however, ultimately the company will offer a modular range of configurations including cross-and straight-conveyors as well as simple and more sophisticated stackers. The cross-conveyor version will keep single batch outputs in sequence for applications such as photos and coupons. The flexibility of the DC-645 programming means that all configurations are simple to set up and easy to adjust to suit customer requirements.

New Product Launches

DSF-5000 High Speed Dynamic Sheet Feeder

An addition to the Duplo dynamic sheet feeder family and next-level option to the established DSF-2000, Duplo’ s new DSF-5000 modular high speed, production level feeder offers a number of enhanced benefits to give greater productivity for near-line finishing and bookletmaking solutions.

Responding to the needs of both the colour market as well as the higher volume black & white cut sheet markets, the DSF-5000 can support the printed output of multiple printers without compromising print production and offers high speed, reliable feeding of a variety of substrates with both ultrasonic double and optical double detection for improved accuracy and reduced waste by preventing the processing of incorrect sets.

In addition, its Optical Mark Recognition (OMR) and barcode readers offer greater versatility in handling variable and personalised print finishing.

The new belt suction feeder, integral buffer and enhanced sheet separation facilities enables consistent and reliable feeding of a variety of substrates at high speeds. The DSF-5000 can feed up to 400 sheets per minute, which is fed from a 610mm high capacity pallet style paper tray. Operators also benefit from automated job set up and changeover, as well as an intuitive, user-friendly PC interface.

To demonstrate the versatility of the DSF-5000, Duplo is showcasing the Digital System 5000 Pro bookletmaking line incorporating two DSF-5000 sheet feeders in a tandem configuration as well as a new twin bin Cover Feeder, a DBM-500 Bookletmaker and Trimmer.

The benefits of Duplo’s modular approach allow printers to add to the system as and when their requirements change. As a result, a solution might incorporate one DSF-5000 for high capacity feed stock or an extra DSF-5000 – a tandem system for maximising productivity as one DSF-5000 could be running while another is re-loaded. Cover stocks could be placed in this second unit, or in the new twin-bin Cover Feed module.

The DSF-5000 can also be combined with Duplo’s versatile SCC slit, cut, crease module to the configuration, which deals with issues of trimming off full bleed print as well as managing digital print cracking problems.

PUR DuBinder

In response to customers’ demand, at drupa, Duplo is extending its single clamp fully automatic DuBinder range by adding a PUR version, making it ideal for short to medium run perfect bound books printed digitally or on coated stocks. PUR binding provides an extremely secure result with its high pull-strength ensuring that each page is firmly bound and can be opened flat without any risk of pages becoming detached.

The closed tank system offers huge cost and productivity benefits compared to open-tank systems, as it does not require draining after each session which incurs wasted material and downtime. Just like Duplo’s standard-adhesive DPB500 DuBinder, it runs at cycling speeds of up to 525 books an hour, and is capable of binding a wide range of materials with a maximum booklet size of 360 x 320mm and minimum size of 120 x 120mm. Cover sheet sizes range from 360 x 696mm and 120 x 250mm.

The versatility of the fully automated DuBinder results in a reduction in set-up times and costs, making it perfect for short run and variable print, whilst its high capacity book production speeds make it equally suitable for longer runs. One of the machine’s key attributes is its easy-to-use integrated touch-screen controls, which facilitates a 35 second set-up between programmes, resulting in a book-bound quality finish with minimal operator skills.

DBM 350/T Mid-Range Bookletmaker

Duplo is also using drupa to introduce a new fully-automatic mid-range bookletmaker/trimmer which fits between Duplo’s established low-end bookletmaker DBM-120/T and its high-end counterpart the DBM-500/T and as such provides an alternative according to production requirements and budgetary needs. Offering stitching heads, speeds of up to 3,000 books an hour, and fully automated set-up, the DBM-350/T is an extremely productive and professional solution. The flexible bookletmaker easily accommodates a range of on-demand applications such as CD and DVD covers through to A4 and A3 booklets of up to 80 pages.

The ability of the DBM-350/T to handle set-by-set and sheet-by-sheet output with equal ease means that it can be connected to Duplo’s collating systems or dynamic sheet feeders, making it ideal for printers making the transition from offset to digital, allowing them to incorporate colour content and variable data into their finishing solutions.

Ultra 205A UV Coater

drupa will also see Duplo International introduce its fully automatic and user-friendly Ultra 205A UV Coater with optional SF-205A Feeder. Delivering variable speeds of between 9m to 36.5m per minute, the Ultra 205A cost-effectively adds high quality, glossy sheen, matte and satin finishes to an array of offset and digitally printed documents up to 521mm in width. The Ultra 205A ensures overall quality of printed output is increased as more vibrancy and richness is added to colours and hues, while ensuring protection from scratching and fingerprints. This makes the Ultra 205A perfectly suited to applications such as book covers, calendars, business cards, brochures, posters and mailers.

In addition, the compact Ultra 205A UV Coater enables easy set-up and operation and features a number of efficiency enhancing attributes. These include a large and intuitive LCD touch screen panel which, via an innovative troubleshooting diagram, allows users to quickly make adjustments. Users also benefit from a self-centering and self-tensioning conveyor belt which automatically readjusts to keep output media neatly stacked.

Further efficiencies are gained thanks to the Ultra 205A’s metering roller speed adjustment which evenly sets the level of coating required, while the built-in self cleaning system ensures post-production labour is reduced.

UJ-500AS Anti-Static Jogger

Designed to drastically improve sheet feeding and combat common problems, such as sheets sticking together due to static, Duplo International has launched its new UJ-500AS anti-static ionised jogger. The machine efficiently jogs and separates sheets in paper stacks, which can then be loaded into printers, collators, folders, cutters and more, and with a small footprint it can be used in any printing or post-printing environment.

Jogging uneven paper stacks with the UJ-500AS prior to loading in print or finishing equipment will noticeably help eliminate feed errors, such as a miss or double feed. Furthermore, the jogger’s unique rapid speed vibration system and ionised air-assisted blowing, effectively reduces static electricity, which is particularly common with digitally printed sheets. It also helps prevent ink residue or set-off, aligns edges and the air blower even assists in drying ink.

Handling paper sizes ranging from 120 x 146mm to 328 x 427mm, the UJ-500AS has a paper loading capacity of up to 480 sheets of 80 gsm. The jogging strength and air volume is fully adjustable according to paper type and static levels and the machine can operate under various settings, such as air only, jogger only or reset timer operation. The jogger also incorporates a time interval mode, which continuously jogs paper stacks for a preset period after the air has stopped.

Mini Friction Collating & Bookletmaking

As part of its new friction fed collating range, Duplo is previewing for the first time the 10-station DFC-100 and 12-station DFC-120 Mini Collators designed for the entry level market. With a host of new improved features such as speeds of 70 sets per minute, the Mini Collators boost productivity and are ideal for smaller print houses, In-plants and offices.

In addition, the higher stacking capacity, improved feed roller designs, neater stacking alignment and new control panels make the Mini Collators even more productive, user-friendly and reliable. The versatile Mini Friction Collators can also be linked to a second tower to make a 20 station or 24 station model as well as a Duplo DBM-120/T Dynamic Bookletmaker to enable full inline bookletmaking for added value finishing.

Versatility and Modularity at drupa 2008

Concludes Sally Dobinson, head of product marketing at Duplo International: “We’re delighted with our wide range of new product innovations and look forward to demonstrating their versatility and modularity at drupa. While digital technology will shape the future of print, offset is here to stay for some time.

As a result, in today’s competitive print environments it’s crucial for printers to use equipment that is capable of handling a mixed workload in order to stay ahead of the competition. The additions to our already wide product portfolio mean that customers can choose the right tool for the right job to maximise productivity whilst minimising cost and investment.”

Duplo Teams Up With Key Partners To Demonstrate End-to-end Digital Workflows

At drupa 2008, Duplo is presenting on its booth a series of live demonstrations of completely automated interactive PDF and JDF based workflow solutions that enable maximum efficiency from job creation, imposition, printing to finishing. By teaming up with selected industry partners, visitors can see the integration of flexible and powerful software with efficient print and finishing equipment used to support a variety of business models.

By demonstrating its print finishing equipment in workflow demonstrations with software companies such as DigiLabs; Pageflex; Ultimate and Objective Advantage, visitors to the Duplo stand will experience just how easy it is to automate production, which offers great cost savings by eliminating human intervention and potential data input errors. In addition, print service providers can maximize production output and extend their business opportunities.

Si Nguyen, product marketing director at Duplo USA comments: “Workflow automation is recognized as a key tool to drive business efficiency so we are pleased to demonstrate to drupa visitors the seamless and easy integration of scalable prepress, print and finishing solutions and how they’ll be able to shorten the time between an order and delivery. The drive for web-to-print automation has turned the focus of innovation to finishing. However, to really maximize the potential of our intelligent finishing equipment, print service providers should evaluate their prepress set up and consider a complete workflow solution to extend customer offerings and enjoy significant productivity benefits.

“As a member of CIP4, we endorse the application of PDF and JDF based workflows to achieve optimum integration and maximum efficiency. We’re pleased to be working with such industry leading companies and look forward to demonstrating the power of such interactive workflows live on our stand.”

PDF/JDF enabled workflow demonstration

One of the live demonstrations sees the production of real print jobs such as business cards initiated via the Pageflex Storefront web submission software which enables template design, flexible layouts, personalization, customization and other powerful graphic design features created specifically for variable publishing. The Pageflex jobs are transmitted via a web service call to Objective Advantage’s Symbio suite of easy to use software management tools, which seamlessly integrates and automates all aspects of print production and order management, then transmits all job instructions to the digital printing device. At the same time, Symbio uses the same original job information to send preview images and job data via JDF to the DC-645 JDF Connector. The JDF Connector provides previews of the job, giving precise operator instructions of how the job is to be loaded. Finally, using the data supplied in the JDF by Symbio, Duplo’s DC-645 Production Color Finisher slits, cuts and creases in one single pass to create the final printed product.

The vacuum-fed DC-645 automatically sets up the tooling to a printed registration mark by using its built-in camera, compensating for the common problem of image drift.

This ensures that each processed sheet is finished accurately and that it slits, cuts, creases and perforates in precisely the right place, reducing waste and ensuring high quality and optimum output. In addition, an air knife lifts and separates each individual sheet to eliminate the problem of static and facilitates mark-free processing. The heavy duty DC-645 is capable of handling up to 26 sheets per minute and can accommodate a wide range of paper weights, ranging from 110 to 350gsm.

Other JDF workflows on the stand will include the production of postcards and greetings cards.

PDF enabled workflow demonstration

Also being demonstrated on the Duplo stand is an automated PDF enabled web-to-finish templated production of photo books created by DigiLabs. DigiLabs offers software that is simple to download and use, enabling easy creation and customization of photo products such as photo books and calendars on customers’ desktops. Once the page layout has been completed with the DigiLabs software, the produced PDF file is transmitted to the Impostrip software from Ultimate.

Impostrip manages imposition workflow, including full control over page position, bleeds, page-spread and scaling, marks and margins.

The photo book pages will then be sent to a Xerox DocuColor 8000AP Digital Color Press and loaded on Duplo’s Digital System 2000 which consists of a DSF-2000 sheet feeder and a DBM-120/T dynamic bookletmaker. Impostrip supports the Duplo register marks and bar codes used in the Digital System 2000. The finished books are then sent through to the versatile ASM-500 Automatic SpineMaster to produce a square spine booklet with a perfect bound finish.

The combination of powerful ‘hot folder’ imposition software and cost effective intelligent finishing solutions provides print service providers with great efficiency and easy of use.

Other PDF workflow applications running on the stand will include a real estate agent’s promotional mailing piece using dynamically created pieces via the Pageflex Storefront as well as personalized investment booklets.

About Duplo International

Duplo International has provided innovative solutions to the office market for more than 30 years and today offers a comprehensive portfolio of office products and solutions through its extensive network of distributors and dealers and partners. Headquartered in the UK, Duplo International also has subsidiaries in France, Italy and Poland.