Rather than have the processes in a line making the machine really long, MGI has put the process in a loop
A factory within a factory
I have written about a number of machines in the past where the solution to increasing efficiency is to wrap a number of processes into one overall fully encompassing device. The thought process is very simple, if the lack of efficiency is due to downtime or machine capacity, then you write this out of the series of processes by doing it all in one.
However, this can be misplaced and the thought process may hold up providing each process does not have a drop in efficiency.
If process one is only 85% as efficient as it can be, the problem can be that the next process will only start with 85% of the whole, meaning that if process two is again only 85% efficient, the overall efficiency now drops to 72%.
Add another process as efficient as the others then overall efficiency is now at 61% of the whole. This compounding of numbers can tumble into what seemed to be a good idea to only be 52% efficient overall after four combined processes.
The AlphaJET 4.0 was developed in partnership with Konica Minolta and MGI
But, get each of these processes as close to 100% efficiency as you can, then the coupling up of multiple processes can not only improve delivery time, it can reduce the manning of other individual machines as well as provide delivery times at record levels.
Having seen many machines fail to live up to this utopian status, it is very pleasing to see one new concept that looks very capable of turning theory into practice, namely the MGI Digital Technology AlphaJET Factory 4.0.
An AlphaJet 4.0 has been installed at Konica Minolta's Center of Competence in Paris
The machine is being released to the market in partnership with Konica Minolta and one has been installed in the new AlphaJET Democenter which has been established for demonstrations in a dedicated Center of Competence at Konica Minolta’s premises in Paris.
Plenty under the surface
MGI has taken the decision to attack the issue of producing high-quality fully finished work in one machine. This means taking four-colour printing, spot UV coating, flat or embossed hot foil finishing, and variable data with personalisation and do everything within one machine.
The layout of what is obviously a large machine is in itself very clever. Rather than have the processes in a line making the machine extremely long, MGI has actually put the processes in a loop. The substrate is transported from one process application to another by the use of what are called Smart Trays which are a series of eleven transport carts, each holding a sheet up to B1 in size.
Electromagnetic linear motors drive each of these Smart Trays around the production loop with virtually no vibration and almost perfect registration.
A vacuum holds the sheets perfectly flat on the Smart Trays and there is a lot of clever engineering to ensure even though these trays are moving around a large loop, they are constantly kept flat and in register for each process.
The MGI has a 4.5-tonne marble slab underneath the printing head section to ensure there is no chance of the Smart Tray or sheet distorting or vibrating. This ensures the 1,600 x 1,600 dpi print head can produce the most exciting of printed output.
To enter and exit the production loop, there are infeed and delivery systems you would see on any other B1 printer be it an inkjet or conventional lithographic press. The AlphaJET 4.0 can print on stock up to B1 in size and has a scope of substrate from 135gsm up to 2mm.
The printing system can produce on a whole series of different substrates with some of the selection being normal box folding board, coated and uncoated papers, folding carton, e-flue cardboard, and synthetics.
Applying the colour
So much for the clever configuration of the production process and the Smart Trays, at the heart of the machine is the need to add colour that can tick all the boxes.
MGI has decided to adopt water-based inkjet heads for the AlphaJET 4.0, as the company feels the future is much more aligned to the stronger eco-credentials of water-based inks. This does not detract from the output of the CMYK set of Memjet DuraLink printing heads.
MGI has decided to adopt water-based inkjet heads for the AlphaJET 4.0, as the company feels the future is much more aligned to the stronger eco-credentials of water-based inks”
MGI claims the depth of colour possible with the five nozzle heads is so capable it can produce over 90% of the Pantone range from the standard colour set. This added to the capacity of the printing heads means there is no banding or marking on any of the sheets meaning the production of high-quality products such as packaging is bread and butter to the AlphaJET 4.0.
MGI claims the five nozzle heads can produce over 90% of the Pantone range from the standard colour set
Depending on the substrate used the MGI engineers have designed into the AlphaJET 4.0 a pre-coating unit that sits within the production loop of the machine. All of this means regardless of the product required, there is no need for additional processing, you just program the step into the process.
Each of the printing heads have self-cleaning functions and easy maintenance and the ability to switch off nozzles to cope with issues with one of them. Colour and ink calibration is standard and the machine comes with FOGRA certification.
The final touches
Next to the colour, within the production loop of the AlphaJET 4.0 there is provision for 2D/3D spot UV coating and all these processes are backed up with inbuilt UV drying systems by either LED, UV, or IR drying capacity.
When you see the machine in action, it really is quite impressive; the clear panels of the AlphaJET 4.0 allow you to see the Smart Trays flying at 18,000 sheets per hour around the production loop with the sheets having one of a number of the processes applied to them.
The machine is controlled with an impressive array of screens displaying the production status of each of the Smart Trays as they rotate around the machine. As well as monitoring the status of the machine, the control system allows the operator to program and schedule each job as well as prepare and pre-flight any of the jobs planned for production.
MGI and Konica have developed a machine which, as they say, is a factory that can be installed in your factory. The ability to scope three or four processes in one and save on time and resources by producing a product in a single process is very impressive. Given the care and detail that’s gone into the engineering, I would be confident you will have a very efficient one-stop printing shop with this machine.
Brian Sims Principal Consultant, Metis Print Consultancy, www.metis-uk.eu
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