Alegro – “The Best Perfect Binder in the World”
It’s been 14 years since Müller Martini presented the Alegro as a world premiere at drupa 2012 in Düsseldorf – I find it striking that the 7,000-cycle perfect binder is still considered best in class, with its high degree of automation thanks to the revolutionary Motion Control Technology and convenient setup wizard.
Hailing from Glasgow, Scotland, Bell & Bain was one of the first graphic design companies to invest in an Alegro back then. “In the evaluation phase, we checked out the competition as well, but the Alegro is light years ahead,” Director at the time Stephen Docherty told us while visiting the drupa booth. I have to say: The man had foresight.
Extremely fast actual order execution times thanks to Motion Control Technology
Then as now, there are three crucial factors that lead to book binders all over the world choosing the Alegro: the fast setup and production times in a very wide range of print run segments and the high product quality. Motion Control Technology makes this possible. It enables extremely fast actual order execution times and maximum profitability. At the same time, it lays the foundation for a wide range of applications. To me, the ability to run a wide variety of formats, from the smallest formats to A3, and even products in the DIN A4 format, landscape in two-up production is a prime example of Müller Martini’s practical approach.
Key aspect of the intelligent machine concept: Thanks to Motion Control, all stations are operated and controlled individually directly with servo technology (within the pressing station, for example) on the Alegro, which has 70 percent fewer chains compared with standard perfect binders. The settings have a direct impact on the product, resulting in a perfect binding quality.
At the same time, Motion Control optimizes the movement flow of the individual process steps tailored to the product, speeds up setup times, and maximizes the production performance in the shortest possible time. Motion Control also reduces the correction of settings to a minimum. For Hansjörg Dietrich, co-owner and Head of Operations & Technology at Swiss Buchbinderei An der Reuss AG, this makes the Alegro commissioned in 2019 and recently upgraded with a Solit PRO three-knife trimmer “the best perfect binder in the world.”
Maximum flexibility and large size range
Its signature features include its high flexibility, as the Alegro enables a wide range of offset, digital, and hybrid applications. Whether large size range, cold emulsion glue, EVA and PUR, two-shot, covers with flaps, or layflat brochures – the Alegro can do it all. The order data for the entire perfect binding line – with configuration options ranging from rod feeders, to signature stack infeeds, customer-specific delivery solutions with ejection/deflection, splitting saw/turnover belt, and buffer systems all the way to front trim units for inline fold processing, three-knife trimmers, destacking solutions, stackers/compensating stackers, shrink-wrap solutions for one-up production/stacking processing, all the way to palletizers– can be entered conveniently using the Book Data Center (BDC) or via the Connex workflow system. To me, that’s true future readiness.
Less maintenance and wear, higher availability
Combined with the intuitive user interface, this not only enables very fast setup and production times, but also reduces training time for machine operators. The shaftless drive system increases efficiency in three ways. First, it reduces maintenance requirements. Second, it boosts availability. And third, it minimizes wear.
In discussions with bookbinders, one topic comes up consistently: the ever lower average print runs for softcover products. And this is where the Alegro shines. Druckerei C.H. Beck in Nördlingen, Germany, for instance, can offer its customers high-quality dispersion perfect binding even for small runs, thanks to the Alegro. “No other perfect binder in this segment can do that,” emphasizes Sebastian Birzele, Head of Bookbinding, during a recent visit to the innovative company.
Alegro Digital for your smart factory
BJU Press in Greenville, whose core business includes the production of softcover books, also wants to produce smaller print runs more cost effectively and faster. This is why the North American company invested in an Alegro Digital last year. The digital version of the proven Müller Martini perfect binder with a maximum performance of 5,000 cycles per hour is the ideal touchless workflow solution for binding digitally printed signatures at smart factories. It provides even more flexibility for short and ultra-short runs, no matter whether printed digitally or offset.
Paper variances of up to +/- 3.25 millimeters within an order, for example due to roller processing, can be automatically compensated for from book to book with up to 5,000 cycles per hour, without compromising performance (book thickness variability). Thanks to the dynamic job change function, different orders can be produced seamlessly one after another within one format family, meaning: The book spine length and block width remain constant, in a thickness range of 2 to 65 millimeters. The automatic job change is done without operator intervention.
Besides the Book Data Center (BDC), there is also an optional barcode Cover Matching System. This enables extremely fast processing of thickness-variable ultra-short runs one after another.
Do you have any questions? Contact me – I’m happy to help!
Yours,
Ronald Reddmann
Product Manager Softcover, Müller Martini
Watch this video to learn why the Alegro is the ideal perfect binder for printing house Druckerei C.H. Beck.
