A single process from blank roll to book block – one single operator runs the entire line – lower costs for smaller runs: The Muller Martini SigmaLine Compact, which is connected inline to an HP T250 digital roll-fed printing press, offers Friesens three significant advantages.
The book division, with an annual output of around 20 million copies, accounts for some 75 percent of the company's turnover – the other divisions, Yearbook, and the FriesenPress account for the remaining quarter – and is the mainstay of the business, which was founded by D. W. Friesens in 1907. The hardcover and softcover segments are balanced. However, both business segments have one thing in common: “Shorter runs have returned – they are trending,” says Byron Loeppky, President/Senior Vice President of Operations (in the picture above on the left / on the right Steve Gardner, Sales Manager at Muller Martini North America), when the conversation turns to the changes in the North American book market since the coronavirus pandemic.
“We are all entrepreneurs”
However, shorter runs per title do not mean ultra-shortrun or even Book of 1 for Friesens. This is because the company, which has been a unique entity in Canada's graphic arts industry since the 1970s, is not active in this business. It is owned by the approximately 600 employees working in 6/24 mode (“everyone is an entrepreneur with us,” says Byron Loeppky). Byron Loeppky describes jobs with runs between 200 and 2000 copies as short runs. Because he assumes that Friesens customers – two-thirds of whom come from the US, one-third from Canada and a few from overseas – will continue to order many book titles in this range, this naturally has an impact on production.
First SigmaLine Compact in Canada
In Altona, where the company entered the digital business a quarter of a century ago, more and more printing is being done digitally. Although this currently accounts for only 15 percent of all jobs (and only 5 percent of the printed paper). But Byron Loeppky is convinced that the digital share will continue to grow in the coming years. In order to keep pace with the HP T250 in finishing, Friesens became the first graphic arts company in Canada to commission a SigmaLine Compact from Muller Martini, which is connected inline to the digital web press, in the summer of 2023.
Long-standing Muller Martini partner
What is special about this investment is that when Friesens evaluated a new solution for book block production, the SigmaLine Compact was not even on the market yet. “We saw SigmaLines II in operation in the United Stats and based our decision for the SigmaLine Compact on what was presented with confidence in Muller Martini to deliver based on previous experiences with multiple Muller Martini finishing line installations,” Byron Loeppky says. "As a long-standing partner, we have great confidence in Muller Martini. The training for the operators and the after sales service are among the best in the business – a real benchmark!”
Three significant advantages
The SigmaLine Compact is used primarily to produce single-color trade books. “But we intend to expand into color trade book work, which we traditionally print offset sheetfed,” says Byron Loeppky, adding, “The new system offers three significant advantages for our book block production. First: the SigmaLine Compact is like one machine in conjunction with the HP T250. They were meant to be together – a single process from blank roll to book block. Second: the simple operation allows one single operator to run the entire line – compared to four cost centers and eight people. Or in other words: the single process with one operator improves the bottom line and gets more work through with fewer people required. And third: the costs are now lower for our smaller runs.”
“Connex is a valuable asset to our company”
The Muller Martini
Connex workflow system has played a significant role in the significantly shorter production times. “We have experienced significant benefits across various aspects of our operations. The automation capabilities of Connex have streamlined our processes, leading to a reduction in labor requirements. Connex is doing all imposition and file management for inkjet jobs going to the SigmaLine Compact. This has not only increased our efficiency but also allowed us to allocate resources more effectively,” emphasizes Steve Voth.
For the Operations Manager at Friesens, one of the most important features of Connex is “its ability to optimize our throughput times in production. This improvement is beneficial in meeting tight deadlines and enhancing our overall productivity. The workflow system ensures consistent outcomes, which improves the quality and reliability of our production. As a bottom line, Connex is a valuable asset to our company, driving automation, reducing labor, increasing speed to press, ensuring consistent outcomes, and providing the customization we need.”
“One-stop shop” for many regular customers
Friesens is also working with partners at another level to intensify the workflow, minimize manual intervention and underpin its good reputation among its many regular customers as a ‘one-stop shop’ from PDF to delivery. For example, the company's Enterprise Resource Planning (ERP) – a software system that supports companies in their core business processes with a unified view of all activities – is being modernized. “This project, which is expected to be completed early next year, is our top priority and will further accelerate our operations,” emphasizes Byron Loeppky.
From the SigmaLine Compact to the Alegro
The book blocks produced on the SigmaLine Compact are bound on an
Alegro perfect binder, which also comes from Muller Martini, with an Orbit three-knife trimmer. This is in use at Friesens alongside another Bolero perfect binder, three Diamant booklines and a Ventura Digital book sewing machine – all from Muller Martini. However, the innovative company is already involved in a future project with a new near-line solution. This is because the Alegro is located in a second plant, which is why the book blocks have to be transported to a different part of the town.
You can also read about the SigmaLine Compact in this blog on the Muller Martini website.