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Ferrostaal opens the house to Morgana


FerrostaalAt the recent open house, held at Ferrostaal New Zealand’s Auckland headquarters, 40 New Zealand printers learned the significance of finishing for their digital solutions

Andy Cooper, general manager of digital print finishing for Morgana Australia and New Zealand, delivered a presentation at the open house, starting with a Frank Romano quote: “The future of digital print will be decided in the finishing department.” Cooper believes Morgana will do well in New Zealand.

He emphasises the company’s focus on digital finishing for the New Zealand market as a no brainer. He says, “What we’ve found is that it’s the smaller countries that do better with digital. Compare your country with Europe; you are very much like the Scandinavians. There are more digital engines where there are a lot of smaller towns. If we look at the UK market in 2003 there was about 1000 digital print engines installed. In New Zealand you had about 500-700 digital print engines installed. Morgana is the market leader in creasing and folding for the digital market and the growth in the market is going up.

Starting in the UK in 1977, Morgana has branched out since it began manufacturing finishing equipment in 1984. The company designs and builds finishing machines, primarily for the digital market. Cooper says, “The demands for digital are different than for offset. When you set up a digital printer, you will probably be using someone who runs off a computer not a trained printer.”

Specifically digital
Cooper continues, “Morgana has designed its machines with the digital process in mind. There are a lot of things we need to consider when we set up the Morgana machines. We realised early on that we would need to prevent creasing and cracking. Digital presses make the paper drier and prone to cracking. Other problems like curling stock and static need to be addressed. We had to make our machines able to handle these kinds of challenges.

“For example, when you are doing rotary scoring, it goes into the paper, but with digital you can scuff over the toner so when you open it up you can see the white off the paper. What we do, we actually push the toner into the media to prevent any sort of cracking. It’s a bit like a letterpress, moving up and down. When we designed the first machine, a little manual hand creaser, it took us 18 months to develop it. Once we had made that we made the fully automatic creaser. That only took three weeks to make. That’s because we had to get the profile absolutely right. If there’s any deviation on the profile you can’t get the creasing right.”

Cooper believes the success the company has enjoyed derives from its commitment to quality, and quality matters in terms of components. Cooper says, “When you’ve got a hardened steel crease, it allows a distance of 50cm or more. However if the machine doesn’t have the hardened steel and the profile right, then you get a weak spot and cracking. So that’s why it took us so long to get the machine right. There are many copies of our machine but they don’t have the hardened steel so they can’t do the same quality job.”

Cooper adds that the digital quality has improved markedly. He says, “In 1999, as a finisher, the biggest problem you had with a digital printer was with the toner. You couldn’t finish it; it would crack. The quality is so much better than it was in 1999.”

Morgana solutions
Cooper says Morgana has the answers for digital print finishing, through its creasing, folding, booklet making and guillotine technologies.
Morgan’s automatic creasing units, the Autocreaser 33 and the Autocreaser 50 run at 8,500 A4 sheets per hour, and 11,000 A5 sheets per hour respectively. Feeding from the bottom of the stack enables users to load the units on the run, reducing downtime for reloading and minimising set up time. The creasing rule and matrix eliminates tearing and cracking. Perforation comes as standard and users can make all the settings and adjustments with the touch screen on which they can store and name an unlimited number of jobs, which makes job recall much easier.

Morgana’s Autofold, a free standing folding unit, comes from a problem that Morgana found where clients would already have a creasing machine and they didn’t want to buy a new creaser. Morgana’s machine, which can go on to the back of any creasing machine, uses a patented flying knife technology that prevents the scuffing and marking on digital stocks that are caused by folding using conventional methods.

Morgana designed its Digifold automatic creasing/folding machine for printers who need to crease and fold digitally printed, heavy weight or cross grained stock. Cooper says its creasing rule and matrix, the DynaCrease, eliminates tearing and cracking. It runs at over 6,000 A4 sheets an hour.

The company says that speed increases when running smaller stocks and is achieved by creasing the sheet without stopping it, yet maintaining an accuracy of +/- 0.1mm.

Picture above shows Andy Cooper, general manager of digital print finishing for Morgana Australia and New Zealand; Mark Goodman of Wellington’s Format Print; and Ian Gillanders, national machinery manager Ferrostaal New Zealand.

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