Duplo DC-645 with IFS

Duplo DC-645 with IFS
Geon’s business unit manager, digital, Mark Stevens, waited until this machine offered true ‘lights out’ production then took the plunge. He hasn’t looked back.

Describe your business

We’re a standalone digital business within Geon Group. We have the ability to use the best processes to get the work through, whether it goes through normal lithographic presses or through the normal digital presses. We do a lot of work that incorporates both systems. 

What have you bought?

We bought the country’s first Duplo DC-645 with IFS unit through GBC Australia in August last year.

What does it do?

It offers ‘lights out’ processing – there’s no operator attending to it. It has a barcode reader that picks up the info from a printed sheet. It does four processes in one: trimming, creasing, folding and delivery under our packing instructions. That would normally take four people to do at different stages. 

Why did you choose this product?

I knew what the front-end product could do but I held off until they had other add-ons to complete the whole process. To me, it was half-baked before. It went to a certain point, but then still had to have human touchpoints. That was the key to me – I couldn’t just have
the front end, I had to have those two components at the back. (which two components?)

Did you consider any other products?

No. There are some other products out there that I’ve seen, but this one had the whole package.

What features do you particularly like?

I like the barcode capability. With our web-to-print option, we place predetermined barcodes outside the trim area. After it gets printed, it gets placed into the tray to accept the work. It scans that barcode and sets the machine up according to predetermined creases and folds and so on. Another plus is the user interface on the PC. That is what makes it so easy, because you’re just following the bouncing ball. You sit in front of it and it tells you everything. Also it is accurate to 0.01 (mm?). You set it up for one sheet and it just keeps going to the last sheet. There’s no deviation to the trims. With this it does the same trim, same crease, same fold in the same position from first print to last print. It’s a remarkable machine. 

Is there anything you wish it had that it doesn’t?

A larger delivery tray. It would allow us to not attend the machine as often. But that’s a minor thing. 

How fast is it?

It depends what you’re running. An SRA sheet from start to finish would go through in five to six seconds. A lot of our processes have been eliminated by placing it through that machine. Speed-to-market is the ultimate to me. The moment we have it through this device, it’s ready for dispatching. 

How reliable is it?

It’s extremely reliable. If there is an issue, it’s generally an operator trying to get it
do something that it’s not capable of doing, which is rare.

How easy is it to use?

Extremely easy. We had training and within a couple of hours we were up to speed. 

Has it saved time and money?

Over two shifts it would be saving us close to one person just in labour. It’s also very accurate, which means less spoilage. There are fewer touchpoints to it, so once it’s set up, you can walk away and it runs. That’s the ‘lights out’ part.  

Has it won you any new business?

On some regular work, it has improved speed-to-market. Things can be activated a lot quicker, where before you had to go through a certain sets of hands. Once it’s printed by night shift, it’s out the door in the morning. 

Were there any difficulties surrounding the install?

There were no difficulties. It rolled on to the floor and we were running some simple jobs through it that afternoon. 

How has the service been?

It’s been very good. If there are any issues or anything we need to ask, they’re straight on to the phone. 

Who do you think this product is right for?

Smaller digital shops, people who are in the stationery market – even though it does a lot more than that – and those small digital sections where labour is a major factor. 

Would you buy another one?

I would. Sometimes I think, I don’t know how I did without it.

 

 


 

Supplier’s response

Geon was looking for a fully automated folding and delivery system to eliminate up to three processes within its existing operation. The DC-645 with IFS system allows consistent slitting, cutting, creasing, folding and delivery, removing the need for guillotining and eliminating manual error. Installation and training for the first DC-645 with IFS system in Australia was a smooth and simple process carried out by GBC technicians and overseen by the national product manager. Geon has been thrilled with the results of the Duplo system. Operators are confident in using the fully-automated system, allowing extra heads for other tasks.

Tim Hawes, GBC Australia

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