From white paper to finished products
Digital printing is much more than a new way of printing on paper. It’s an on-demand mindset
that disrupts conventional production models. The technology allows effi cient short runs, lower
labor costs and faster turnarounds. And it changes the way service bureaus, commercial printers,
direct mailers and book publishers process paper. Today, print production is a completely fl exible
process that opens up entirely new, unimagined and exciting possibilities.
2
New Generation 8
3 Global distribution network Worldwide service support Modular equipment Security / Content control
Powerful systems for digital paper processing Hunkeler develops and supplies innovative solutions for continuous
feed paper processing througout the digital print process: Modular,
high-performance systems that present the paper to the digital
press and then further process the printed paper through to the end
product. Completely integrated systems are produced in close
partnership with the leading digital press manufacturers. Centrally
controlled, these systems guarantee the highest productivity, fl exibility
and process reliability.
Expert partnership Success in paper processing applications requires knowledge and
experience. We at Hunkeler have been continuously developing and
refi ning this expertise together with our customers since 1922. With
best-in-class engineering, machine components and control units, we
have successfully mastered increasingly complex system integration.
So that everything runs perfectly One reason for the reliability and effi ciency of our systems is the
high level of service support. Around the clock and worldwide.
Individual service modules allow Hunkeler to ensure support that is
exactly tailored to your wishes. Our service hotline with Hunkeler
Remote Assist – plus our spare parts and aftersales service – guarantee
the highest equipment availability. With comprehensive service and
operating documentation to assure professional attention and the
highest possible machine productivity.
Security becomes transparentWith the Hunkeler Control Platform we offer you hardware and
software for quality control and document tracking throughout the
printing process. Scalable design enables customized, user-specifi c
solutions. Thanks to fl awless web inspection and tracking, you will
have good answers to these questions and more in the future. It‘s
always better to be on the safe side, with Hunkeler as your trusted partner.
Hunkeler's versatile dynamic functions such as Dyna-Cut and Dyna-
Scan offer dynamic scanning, cutting and stacking of variable sheet
lengths with automatic changeover during ongoing production.
The result is noticeably higher fl exibility and profi tability by saving
unwanted waste.
4 Hole punching with PP6Paper web dedusting iPEM Quality control with WI8 Roll production with center cut
Roll to Roll Solution The Hunkeler roll to roll solution with different confi gurations for
continuous feed digital presses. High-speed Hunkeler unwinders
and rewinders ensure effi cient, productive downstream processing
in the transactional, direct mail, print-on-demand and packaging
segments, coupled with inserters and other fi nishing systems.
Technical Data* | Roll to Roll
POPP7 Gen8 Gen8-Wide
(UW7) (UW8/RW8) (UW8-W/RW8-W)
Max. roll diameter: 54” (1370 mm) 54” (1370 mm) 54” (1370 mm)
Web width: 6.5” – 30” 6.5” – 22.5” 8” – 30”
Production speed: up to 220 m/min up to 254 m/min up to 305 m/min
up to 720 ft/min up to 833 ft/min up to 1000 ft/min
Paper weights: 40 – 300 gsm 40 – 300 gsm 40 – 350 gsm
Roll weight max.: 800 kg (1760 lb) 900 kg (1984 lb) 1500 kg (3307 lb)
Options: see data sheets
Statements
Invoices
Personalized letters
Transactional
Unwinder
UW8|UW7
Printing System
Rewinder
RW8
Web Inspection
WI8
Unwinder UW8
for Inserters
Printing SystemRewinder RW8-W
Unwinder UW8-W
5
FS6 options
Technical Data* | Roll to Stack Solution Gen8
Max. roll diameter: 54” 1370 mm
Web width: 8” – 22.5” 203 – 571 mm
Production speed: up to 590 ft/min up to 180 m/min
Paper weights: 27 lb offset/book – 110 lb cover 40 – 300 gsm
Stack height: up to 10“ up to 254 mm
Format length: 5“ – 19“ 127 – 482 mm
Variable chip-out: 1/4“ – 2“ 6.3 – 50 mm
Applications: 1up – 4up
Options: Dyna-Cut, Tracking, LS8-30 B2+ stacker
Roll to Stack SolutionHigh-performance Gen8 fi nishing line for the roll-to-stack production
with CS8 cutting module, separation module and LS8 stacking module.
Web widths of up to 22.5 inches will be processed at up to 590 ft/min.
DynaCut function for variable-format production allows cut-off length
changes while running. Gen8 technology is ready for future printing
speeds. Reliable processing of demanding products in full-color on
coated and uncoated standard paper, from light-weight to heavy-
weight grammages. The new Hunkeler Workfl ow Manager provides
user-fi endly and convenient operation of the production line.
Separating
Linear cuttingCross cutting
Sample Workfl ow:
4-up production
Stacking
Stacker LS8
Length- and Cross
Cutter CS8
Printing System
Offset Separator SE
Cutter CS8-I, cross and linear cutting Cutter CS8-II, cross cut, chip-out, linearcut Cutter CS8-II, perforating and cross cutting
Web Buffer
WB8
Fan-Folder
FS6
Web Inspection
WI8
Printing System
Register mark
printing unit
Roll to Fan-Fold Solution The modular Hunkeler roll to fan-fold solution. In 2-up production
individual processing of the two web halves is possible. Combined
use of three different functions is possible in a single DP8 dynamic
processor module (static and dynamic perforation in the vertical and
cross direction, dynamic fi le hole punching, and folding perforation).
Reliable, inline high-speed operation with continuous feed printing
systems in a space saving package with modular options that include
a stack cart system, high capacity stacker, and web inspection.
Technical Data* | Roll to Fan-Fold
Max. roll diameter: 54” 1370 mm
Web width: 8” – 20.5” 203 – 520 mm
Production speed: up to 720 ft/min up to 220 m/min
Paper weights: 16 – 40 lb bond 56 – 160 gsm
Stack height: 39.4“ 1000 mm
Folding perforation: 7“ – 14“ (static) 178 – 355 mm (static)
Folding height: 7“ – 17“ 178 – 432 mm
Options FS6: Shingle Belt Delivery, Stack Cart System, High Capacity Stacker,
Stack Turning
Options PP6: File hole punching, Register Mark printing, different cross
perforation cylinders
HWM
Dynamic Processor
DP8
Unwinder
UW8
Unwinder
UW8
6
Technical Data* | Roll to Stack with DP8 – WM8 – LS8
Max. roll diameter: 54” 1370 mm
Web width:* 16” – 20.5” 406 – 520 mm
Production speed:** up to 590 ft/min up to 180 m/min
Paper weights:** 16 – 35 lb bond 60 – 130 gsm (max. 300 gsm)
Stack height up to: 10“ 254 mm
Variable chip-out: 1/4“ – 1“ 6.3 – 25 mm
Format length: 5“ – 14“ 127 – 482 mm
File hole punching: 2-, 3-, 4 hole pattern Ø 5.5 – 8 mm
Preferred dies:
* 22.5" / 571 mm with underpath of DP8
** depending on production path
Options: Offset separator SE, Gutter cut, Web Folder WF8
Vertical and cross perforations Full bleed products with CS8-II Quality control with WI8 Web merging with WM8
Roll to Stack Solution with DynamicProcessor and Web Merger The DP8 dynamic processor module is the fi rst solution that combines
perforation in the vertical and cross directions along with punching:
all in one unit. «Dynamic» means the ability to change the perforating,
punching or hole pattern from sheet to sheet.
It is particularly interesting for transpromotional applications or perso-
nalized mailers. Coupons, payment slips and other elements can be
integrated into practically any type of document, even those with forms
that vary with each sheet.
Vouchers
Billings
Policies
Stacker LS8
Web Merger WM8
Web Buffer WB8 Printing System
Dynamic Processor DP8
MergingCross cutting
Center cutting
Merging Process:
Stacking
Offset Separator SE
Transpromo
Length- and Cross
Cutter CS8
Unwinder
UW8
7 Coupon with safety features Pattern-Plugin: easy job setup Perforating and Punching Effi cient 2-up production
Roll to Stack Solution with Dynamic Processor Dynamic perforation and punching combined in a modular concept
of the DP8 dynamic processor module. In 2-up production individual
processing of the two web halves is possible. Combined use of three
different is possible in a single module (dynamic perforation in the
vertical and cross direction, and dynamic fi le hole punching).
Technical Data* | Roll to Stack with DP8
Max. roll diameter: 54” 1370 mm
Web width:* 8” – 20.5” 203 – 520 mm
Production speed:** up to 590 ft/min up to 180 m/min
Paper weights:** 11 – 53 lb bond 40 – 200 gsm (max. 300 gsm)
Stack height: 10“ 254 mm
Variable chip-out: 1/4“ – 2“ 6.35 – 50.8 mm
Format length: 5“ – 14“ 127 – 482 mm
File hole punching: 2-, 3-, 4 hole pattern Ø 5.5 – 8 mm
Preferred dies:
* 22.5" / 571 mm with underpath of DP8 and up to 300 gsm paper weight
** depending on production path
Options: Stacker LS8, Web Merger WM8, Web Folder WF8
Web Buffer WB8 Printing System Web Inspection
WI8
Stacker LS8-30
Offset Separator SE
Dynamic Processor
DP8
Performance DP8: Performance DP8: Performance DP8:
s e
Dynamic linearand cross perforation
Dynamic filehole punching
Dynamiccross scoring
Static linear scoring
Length- and Cross
Cutter CS8 Unwinder
UW8
Dynamic Processor DP8 – different configuration possibilities for perforation, punching, scoring and web inspection
WI8 Web Inspection Linear perforation Cross perforation Linear scoring Cross scoring Punching
DP8-I-LDP8-I-L
DP8-II-LDP8-II-L
DP8-I-LLDP8-I-LL
DP8-II-LLDP8-II-LL
DP8-I-P-LDP8-I-P-L
DP8-I-P-LLDP8-I-P-LL
8 Full bleed products with CS8-II Effi cient direct mail production Cross folded direct mailers
Postcards
Selfmailers
Flyers
Cross cuttingFolding
Perforation Folding Process:
Cross foldingDelivering
Technical Data* | Roll to Sheet Solution with Folder WF8
Max. roll diameter: 54” 1370 mm
Web width:* 10” – 20.5” 254 – 520 mm
Production speed: up to 590 ft/min up to 180 m/min
Paper weights:** 16 – 43 lb bond 60 – 160 gsm
Final format length:*** 5.5“ – 62“ 140 – 1575 mm
Variable chip-out: 1/4“ – 1“ 6.3 – 25 mm
* 22.5" / 571 mm with underpath of DP8
** folding: 40 –130, perforating: 40 – 200, scoring: 120 – 250, punching: 60 – 120
*** with chip-out
Buckle Folder
Web Folder WF8
Mailing production with web folderProduction of direct mail and a selfmailer from pre-printed roll to folded
end-product at a web speed of up to 180 meters per minute. Mail
pieces are dynamically perforated or scored in both vertical and cross
direction using a DP8 dynamic processor with optional punching.
The paper web is linear fold, registered superimposed in a WF8 web
folder. A CS8 cutting module performs cross-web chip-out before the
sheets are presented in-line to the folding machine. The compact new
WI8 web inspection system employs state-of-the-art CIS technology
(contact image sensor) for quality monitoring while production is in progress.
The new Hunkeler Workfl ow Manager HWM makes job setup, operation
and monitoring of the production line centralized and convenient.
Additional Web merging (WM8)
Dynamic Processor DP8
Direct Mail
Length- and Cross
Cutter CS8
Unwinder
UW8
9Dynamic vertical and cross scoring 300 gsm post cards (up to 4-up) Vertical and cross perforations Folded mailing
Premium quality direct mail production with the latest generation of machinesProducing fi rst-class, four-color printed mailings even on coated paper
from the roll to the cut and folded end-product. Dynamic punching,
vertical and cross scoring or perforation is performed in the DP8
dynamic processor module. The double cross-cutting cylinder in the
CS8 cutting module produces full-bleed documents. The cross-cutting
cylinder in the CS8 can be equipped either with two knives for
variable chip-out, or with one cutting knife and one perforating blade
to produce dynamic folding perforations.
The integrated WI8 Web Inspection System based on the latest high-
speed CIS technology for high-end quality and integrity control.
Technical Data* | Roll to Stack with Folder/Merger
Max. roll diameter: 54” 1370 mm
Web width: 10” – 20.5” 254 – 520 mm
Production speed: up to 590 ft/min up to 180 m/min
Paper weights:* 16 – 43 lb bond 60 – 160 gsm
Variable chip-out: 1/4“ – 1“ 6.3 – 25 mm
Format length: 5“ – 14“ 127 – 482 mm
Stack height: 10“ 254 mm
* folding: 40 –130, perforating: 40 – 200, scoring: 120 – 250, punching: 60 – 120
Technical Data* | Roll to Sheet, Direct Mail CS8
Max. roll diameter: 54” 1370 mm
Web width:* 8” – 20.5” 203 – 520 mm
Production speed: up to 600 ft/min up to 180 m/min
Paper weights: 16 – 53 lb bond 60 – 200 gsm (max. 300 gsm)
Final format length:** 5.5“ – 62“ 140 – 1575 mm
Variable chip-out: 1/4“ – 2“ 6.3 – 50 mm
* 22.5" / 571 mm with underpath of DP8
** with chip-out
Buckle Folder
Highest fl exibility with Folder/Merger Production of direct mails and selfmailers from pre-printed roll to
folded end-product. Mail pieces are dynamically perforated or
creased in both cross and vertical direction using a DP8 dynamic
processor with optional punching. The paper web is linear merged
or fold, registered superimposed in a WF8/WM8 web folder/merger.
A CS8 cutting module performs cross-web chip-out before the sheets
are presented in-line to the folding machine. The compact new WI8
web inspection system employs state-of-the-art CIS technology (contact
image sensor) for quality monitoring (color, register, codings, variable
data, etc.) while production is in progress.
Stacker LS8
Dynamic Processor
DP8
Web Merger
WM8
Web Inspection
WI8
Length- and Cross
Cutter CS8
Length- and Cross
Cutter CS8
Unwinder
UW8
Unwinder
UW8
Web Folder
WF8
Dynamic Processor
DP8
10 Premium photo book Soft cover book Hard cover book Up to 4-up book production
Roll to Roll – Non-stop SolutionRoll-to-roll high performance production. On-the-fl y roll change on the
new RS8 Roll Splicer and new TR8 Turret Rewinder. Designed for web
speeds of up to 243 m/min. Non-stop roll change in a wide variety of
paper weights ranging from 50 to 300 gsm. Increase in productivity
of up to 30 percent compared to manual roll change, depending on
print speed and roll length. Non-stop feature and paper waste
depending on printer model.
Technical Data* | Roll to Roll Non-Stop Solution
Max. roll diameter: 50" 1270 mm
Roll weight max.: 2000 lb 907 Kg
Web width: 11” – 22” 279 – 558 mm
Production speed: up to 800 ft/min up to 243 m/min
Paper weights: 34 lb offset/book – 110 lb cover 50 – 300 gsm
Photobooks
Hard- and Softcover
Manuals
Publishing
Non-Stop
Roll Splicer RS8
Printing System
Non-Stop
Turret Rewinder TR8
11 Folded / stacked book signatures Thread sewn book binding Optional inline perfect binding
Loose Leaf Book Block Production with Roll to Stack Line The modular Hunkeler roll to stack solution for stacked sheet output
with continuous feed digital printing systems. Innovative non-stop
stacker with rotary single cut sheeter or variable chip-out double cutter
for full bleed products. For example, cleanly offset-stacked sheets
can be output for further downstream processing, such as perfect
binding. Loose sheet offset stacks from 1-up to 4-up production.
Flyfolder Book Solution The Flyfolder book solution is an equally innovative and revolutionary
simple concept for modern Book-on-demand production. The format
change-over between 4-page and 6-page signatures is fully automatic,
which means without any manual intervention, «on the fl y».
• Book of 1
• Fully automatic changeover between 4- and 6-page signatures
• Automatic change of book length and book thickness
• Excellent Book block quality thanks to book block gluing
Technical Data* | Loose Leaf Book Block Production
Max. roll diameter: 54” 1370 mm
Web width: 8” – 22.5” 200 – 571 mm
Production speed: up to 590 ft/min up to 180 m/min
Paper weights: 27 lb offset/book – 110 lb cover 40 – 300 gsm
Stack height: up to 10“ up to 254 mm
Format length: 5“ – 19“ 127 – 482 mm
Variable chip-out: 1/4“ – 2“ 6.3 – 50 mm
Applications: 1up – 4up
Options: Vertical peforations in CS8 for book signatures or
tear-off perforforation, Autoregister, Dyna-Cut, Tracking*
Technical Data* | Flyfolder Book Solution
Max. roll diameter: 54” 1370 mm
Web width: 17” – 19.5” 432 – 495 mm
Production speed: up to 436 ft/min up to 133 m/min
Paper weights: 47 – 68 lb book 70 – 100 gsm
Cut length: 7“ – 14“ 178 – 356 mm
Performance: up to 600 delivery cycles per hour
Options: Front/Back verifi cation, Tracking
Longitudinal
Perforator LP6Flyfolder FB6Star Wheel Delivery
SD7-II- Flyfolder
Sample Workfl ow:
Automated change-over
StackingStacking GluingGluing
Folding Folding
Cross cutting Cross cutting
Turning Turning
Cross Cutter CS6-HS
Separating
Linear cuttingCross cutting
Sample Workfl ow:
3-up production
Stacker LS8
Printing System
Offset Separator SE
Web Buffer
WB8
Web Inspection
WI8
Stacking
Folding
Perfect Binding
Book Block Destacker
Longsheet-tray/
stack delivery TB8
Vertical perforations in cutter CS8
Length- and Cross
Cutter CS8
Unwinder
UW8
Unwinder
UW8
12 Thread-sewn book binding Soft cover book Front/ Back print verifi cation
Production of high-quality softcover and hardcover books In-line premium quality book production from the printed roll.
The paper is fed to the thread sewing machine from the new UW8
unwinder and through the Generation 8 CS8-I cutter. The Universe
Web book sewing machine performs several processes on the fl y.
These are creasing, folding, collecting folded sheets in 8, 12, 16 or
more pages to form one signature, as well as stitching and output.
All process steps are executed one after each other. The book blocks
are then fed into a multifunctional book production line.
Technical Data* | Book Solution (thread sewing)
Max. roll diameter: 54” 1370 mm
Web width: 8" – 22.5” 200 – 571 mm
Format length:* 5.9" – 16.5" 150 – 420 mm
Paper weights: 27 – 135 lb book 40 – 200 gsm
Production speed:* 436 ft/min 133 m/min
* Depends on book thickness / page count per book
Catalogues
Magazines
Booklets
Optional inline perfect binding
Publishing
Length- and Cross
Cutter CS8
In this machine, the hardcover preparation is performed by applying
cover sheets and gauze or in the case of paperback production,
with the softcover. The line is completed by the three-knife trimmer,
that features automatic size change without changing parts.
Unwinder
UW8
13
Output SolutionsPossibilities:
Pre-glued book blocks with SD7 Budget Binding High performance robot system Stack separator / Destacker
Technical Data* | Book Block Solution with SD7-II
Max. roll diameter: 54” 1370 mm
Web width: up to 30” up to 762 mm
Production speed: up to 656 ft/min up to 200 m/min
Paper weights: 40 – 100 lb book 60 – 150 gsm
Folds: 1 to 2 plow folds (2 to 4 layers)
Format length: 7 – 14“ 178 – 356 mm
Book block thickness: up to 2“ up to 50.8 mm
Stack height: up to 4 3/4“ up to 120 mm
Productivity: up to 600 delivery cylces per hour:
- for format 6x9“: up to 4100 book blocks with 96 pages
- for format DINA5: up to 4500 book blocks with 96 pages
- for format DINA4: up to 2400 book blocks with 96 pages
Options: Dyna-Cut, Tracking
Inline Solution Book Solution:
High-performance Book Block Solution with Star Wheel Delivery The modular book solution for the production of glued book blocks
inline or offl ine for continuous digital printing systems up to a paper
web width of 30 inches. Processing of 4, 6 or 8-page signatures
with quick setups and format changes. The high-performance cross
cutter CS6-HS and the star-wheel delivery SD7-II guarantee non-stop
production up to 200 m/min (656 fpm) with over 600 output cycles
per hour. In one stacking cycle, several book blocks are delivered.
The system is characterized by modularity and fl exibility coupled with
simple and safe handling for further processing thanks to integrated
book block gluing and perfectly fl at book stacking.
The book-on-demand line can be used as a fl exible near-line
solution or as an inline system and is designed for the low to
medium volume segment.
Plow Folder PF7
Star Wheel Delivery SD7-II
Transport Belt
Book Block Destacker
Cart Solution
CustomizedRobot Solution
Web Buffer WB8
Printing System
Cross Cutter CS6-HS
• High availability of the system
• Non-Stop high performance system for continuous production
• Automatic change of book length and book thickness
• Excellent Book block quality thanks to book block gluing
Roll Splicer
RS8
14 Pre-glued book blocks with SD7 Dynamic book length Dynamic book thickness Thread-sewn book binding
Hard- and Softcover
Thread sewing
Budget Binding
Signature folding types: Number of pages Signature width Max. paper weight Stack
Parallel fold 4 5 – 10.5“ 150 gsm 1-up
Roll fold 6 5 – 10“ 105 gsm 1-up
Double parallel fold 8 5 – 7.5“ 80 gsm 1-up
Loose leaf 4 5 – 17.5“ 100 gsm 1-up
Books on Demand, variable format sizesThe Hunkeler book block solution is distinguished by high fl exibility,
fast and easy changeover, and excellent book block quality. Books are
produced on demand in variable format sizes, thanks to fully
automatic longitudinal format changeover, a high-performance
trimming module and a unique star wheel delivery system.
The PF7 plow folder processes paper webs up to 30 inches web
width into 4-, 6- or 8-page signatures.
Publishing
The integration of the production line into a JDF/JMF workfl ow is
possible on a customer-specifi c basis. The glued book blocks assure
simple, secure handling for post-processing. An on-board tracking
system monitors for document integrity. Book blocks will be perfect
bound nearline, with a barcode checking system to insure proper book
block to cover matching. The system will also support two alternative
fi nishing processes. The PF7 will also glue «budget bound» brochures
and books, a low-cost approach for short shelf-life products.
15Perfect-bound books without milling Budget Binding Loose leaf book stacks Front / Back print verifi cation
Stacking
Turning
Cross cutting
Loose LeafLoose sheet stacks for thread sewing or stitching
GluingCross cutting
Perforations
Folding
FoldingStacking
Turning
Folding
Folding
FoldingCross cuttingCross cutting
Double parallel fold8 - page signatures
Gluing
Cross cutting
Perforations
Perforations
Folding
Folding
Stacking
Turning
Folding
Perforations
Folding
Cross cuttingCross cutting
Gluing
Roll fold6 - page signatures
Gluing
Cross cutting
Perforations
Folding
Stacking
Turning
Parallel fold4 - page signatures
16 Stitched brochures Budget bound brochures / books Brochure with integrated vouchers Inline saddle stitching / trimming
High Performance Booklet Production Full-color personalized brochures with a variable number of pages.
The solution for high speed production of examination brochures,
leafl ets, manuals, direct mailers, and other saddle-stitched products
from a roll. Optionally the line can be equipped with the dynamic
processor DP8, and cover and sheet inserting. Process includes the
paper web feeding from the Unwinder UW8, cross cutting in the CS8
and gathering, folding, stitching, trimming in a saddle-stitching system.
Trimmer
Booklet / Manuals
Examination brochures
Voucher booklets
Commercial
Unwinder
UW8
Length- and Cross
Cutter CS8
Horizon Stitchliner
Technical Data* | UW8 - CS8 Booklet Production Line
Max. roll diameter: 54” 1370 mm
Web width:* 11” – 20.5” 279.4 – 520 mm
Cut length: 8.3 – 13.7“ 210 – 350 mm
Production speed: up to 600 ft/min up to 180 m/min
Paper weights: 35 – 140 lb offset 52 – 210 gsm
Productivity: up to 6000 booklets per hour, format A4, 24 pages
* Depending on stitcher
Options: Cover and Sheet inserting unit, Dynamic processor DP8, Dyna-Cut
17 Additional books with Combi Front / Back print verifi cation
Booklets and Books Combi-Solution With this combined solution it becomes possible to produce saddle-
stitched brochures or loose sheet stacks for perfect bound books.
The centerpieces of this digital production line are the CS8 Cross
Cutter and the Overpass unit. The paper web is cut into single sheets
by Hunkeler‘s precision rotary cutting system. The Overpass unit
allows quick and easy diverting of the output to the inline saddle-
stitching system or to the conveyor belt for stacked book blocks
(e.g. for transfer to a near line perfect binder).
Technical Data* | Budget Binding Solution with SD7-II
Max. roll diameter: 54” 1370 mm
Web width: up to 30” up to 762 mm
Format length: 7 – 14“ 178 – 356 mm
Production speed: up to 656 ft/min up to 200 m/min
Paper weights: 40 – 100 lb offset 60 – 150 gsm
Productivity: up to 6'400 booklets per hour, format A4, 24 pages
Options: Dyna-Cut, Tracking
Printing System
Web Buffer WB8
Stacker LS8
Offset Separator SE
IBIS Stitcher/Trimmer Overpass unit
Plow Folder PF7
Star Wheel Delivery SD7-II
Web Buffer WB7-30
Printing System
Glued Booklet and Book SolutionThe high performance Hunkeler brochure solution for the production
of variable on demand booklets offl ine or inline with continuous feed
digital printing systems. The optional Budget Binding device in the
Plow Folder book line enables the production of a completely glued
books or brochures without cover in just one process step. This pro-
duction method is ideally suited for products and applications that are
only used for a short time, e.g. examination documents or visa forms.
Dynamic glued brochures Examination Booklets
Cross Cutter CS6-HS
Length- and Cross
Cutter CS8
Unwinder
UW8
Unwinder
UW8/UW7
Technical Data* | Combi-Solution Books and Booklets
Max. roll diameter: 54” 1370 mm
Web width: 8” – 22.5” 203 – 571 mm
Production speed: up to 500 ft/min up to 150 m/min
Paper weights: 27 – 200 lb offset 40 – 300 gsm
Format length:* 5“ – 14“ 127– 482 mm
Stack height: 10“ 254 mm
* 19" with LS8 stacker / 30" (B2) with LS8-30 stacker
Options: Cross cut with chip-out, Dynamic processor DP8, Dyna-Cut, Tracking
18
Hunkeler DocuTrimIn the high-performance range, printing systems only reach their full
potential with effi cient fi nishing systems. The Hunkeler DocuTrim is a
multifunctional system for online sheet processing that satisfi es the
requirements of the latest generation of printers. It produces online on
sheet-fed printing systems and also works offl ine. With its individually
combinable cutting, perforating and creasing in the dynamic multi-
processor (DMP), the system already addresses the market require-
ments of tomorrow. It enables the cutting of various formats and positi-
on-independent slit cuts and chip-outs. Thanks to the system‘s modular
structure, the wide range of solutions can be individually extended.
Technical Data* | DocuTrim
Production speed: 12.000 Sheets/h A4, B4, SRA4
10.000 Sheets/h A3, B3, SRA3
Sheet format Input: min. 180 x 152 mm (H x W)
max. 520* x 520 mm (H x W)
Sheet format output: min. 148 x 105 mm (H x W)
max. 520 x 520 mm (H xW)
Stack height up to 220 mm
Side trimming: 6 – 25 mm
Gutter cut: 6 – 12 mm
Perforation tools: Horizontal perf. 0 – 6 Pcs. | Vertical perf. 0 – 6 Pcs.
Paper weight: 60 – 250 gsm*
*certain limitations for formats and papers apply
DocuTrim offline configuration with pile feeder
DocuTrim
W
W
H
H
Statements
Commercial
Mailings withmixed paper
Universal Sheet Finishing
Pile Feeder
* *
* Optional Interface to folder or booklet-maker
Configuration left
Inline Offl ine with Pile feeder
DMP 2. Slot
DMP 1. Slot
DM
P 2
. S
lot
DM
P 1
. S
lot
DMP 2. Slot
DMP 1. Slot
DM
P 2
. S
lot
DM
P 1
. S
lot
DocuTrim online with Digital Printing System
CuttingPrinted sheets can be cut into a number of smaller sheets, collated
and placed in groups as an offset stack. With bleed-off applications,
the net format is achieved with a cut-out.
Dynamic perforationDynamic perforation can be carried out with horizontal and vertical
lines. Up to 6 vertical and 6 horizontal perforating tools can be used
for creating a different variety of perforation patterns. The patterns
can be static or can be dynamically triggered by a data matrix code.
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DocuTrim Printing System
20 High availability of spare parts Worldwide service network Hotline and Remote Assist Latest support technology
The right decisionWith your decision to go for a Hunkeler production systems you
already have taken the fi rst important step a productive system with a
high availability. The next step to secure reliability, high productivity
and a long service life is to cover all your service needs.
Combine the service products that best match your needs to secure
your ability to perform and to achieve optimal availability.
Modular and individualized serviceService products that are tailored to suit customer needs and
complement each other can be combined into an individualized
service package, thereby ensuring outstanding availability at a great
value – day after day.
Service products in all important phasesWith our service products, you benefi t from expert support in all
phases. With the “huncustomer” range of services, you have a strong
partner on your side.
Remote Assist A “remote connection” makes it possible to give external Hunkeler
experts secure access to your Hunkeler system. The remote
connection enables rapid error analysis, troubleshooting, data
backups or simple production support. The customer is fully
integrated into the process at all times. In other words, access is
controlled by the customer, who can terminate connection whenever
desired. Today, Hunkeler Remote Assist identifi es problems online
and gives you assistance as if a technician was on site. No matter
where your system is, our expert service team is always close at
hand.
Hunkeler Remote Assist is a complete package of various online
services.
Hunkeler Service 4.0
Immediate expert-support worldwide
Greater Effi ciencyhigher productivity
More profi t thanks to higher availability
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Service
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Hunkeler Workfl ow Manager – HWMOur software system for production planning and
process optimization
With the Hunkeler Workfl ow Manger HWM, modules and lines are
networked so that jobs can be produced optimally. The selected
apps support the fast and easy creation of productions through a
visual display of the print formats including register marks and 2D
codes. Faster job and line set-up increase effi ciency and fl exible job
assignment leads to greater product diversity.
The product-oriented job defi nition and simple operation through the
graphical editor offer unlimited possibilities without job restrictions.
Our job defi nition workfl ow becomes simple and the job data is
automatically and correctly generated.
The jobs can be created directly on the line or conveniently in the
offi ce, for example in print preparation and sent to the corresponding
lines. This signifi cantly reduces setup work and speeds up the
production of print jobs.
Hunkeler is constantly working on further apps that offer the customer
added value and can be installed on the HWM at any time.
The Hunkeler Data Capture HDC software is used to pass Hunkeler
machine data to third party systems. Hunkeler is collecting operating
data from its controllers and is making this data available for retrieval
to 3rd parties with a web server or a MQTT Broker.
Functionality
The data supplied by the line controllers is collected by the Hunkeler
Data Capture HDC and made available to external display and
analysis systems through a web server or MQTT Broker.
Analytics requires the Hunkeler Data Capture.
Hunkeler Data & Analytics
Line Line
Analytics
Data Capture
Third-party analytics system
Production data acquisition
Open interface for integration
Operating data
Reports
Workfl ow ManagerWorkfl ow Manager
22
Web Inspection System A web inspection system checks the quality and
content of the printed pages in terms of colors,
positions, contours, smearing, jet-outs, etc.
State-of-the-art digital contact image sensor tech-
nology scans the entire width of the paper web,
creates high-resolution images of the printed
image and compares these with the ‘golden sam-
ple’ to carry out many different kinds of quality
and content checks. The system ensures
consistently high print quality for a diverse
range of applications.
Printing and content errors are identifi ed at an ea rly
stage to trigger immediate action, reducing both
downtime and paper waste.
WI8 Web Inspection System The Hunkeler Control Platform represents a high-performance system
for production monitoring and quality control. With the WI8 Web
Inspection system you can check quality and content of the printing
on each page in terms of colors, positions, contours, smearing, jet-
outs, data validation, etc. It is always possible to update it with new
functions and extend it to a complete tracking solution.
Simplex and duplex colour variants The system can be integrated as a simplex and duplex colour variant.
Due to the very compact design, this can be integrated in various
modules or even in printers. Alternatively, it is also available as a
stand-alone solution.
The basic equipment includes the CIS (Contact Image Sensor) scan-
bar per side, a 22" wide multi-touch LCD operator monitor and the
controller box.
Touchscreen for operation
Controller box
CIS Scan bars
IPIIntelligent Print Inspection General Web
Inspection System
Does not need «golden sample» Needs «golden sample»
Data Matrix Code(Decoding & Verification) Printer calibration
Inspection of variable data book/transactional
Needs dedicated calibration page
WI8Camera System
TrackingHunkeler Control Platform – HCP
• Duplex or Simplex• Standard available width: 22" • 14", 30", 42" available
upon request
Web Inspection
Web Inspection WI8 with printer integrated Web Inspection WI8 as stand-alone solution
Web Inspection WI8 with Dynamic Processor DP8 Web Inspection WI8 with Length- and Cross Cutter CS8
Dyna-Scan
Hunkeler's versatile dynamic function Dyna-Scan offer dynamic scanning of variable sheet lengths with automatic
changeover during ongoing production. The result is noticeably higher fl exibility and profi tability.
Intelligent Print Inspection – A new dimension in print inspection
IPI stands for Intelligent Print Inspection and enables a new way of performing print inspection. In traditional print
inspection, the operator creates the template for image matching (Golden Template). A number of features to
be checked are selected on a printed page that has been found to be “good”.
IPI opens another way to create the template for image matching: Instead of having the template set by the
operator, the IPI system uses the raw print data directly sent from the printer controller to the inkjet print heads.
In transactional printing, errors in the printing of variable data can be detected without, for example, the address
information being known in advance. Furthermore, it is possible to detect print errors in graphics and images, even
if they occur only once in an entire print job.
Prepress
Print Server
Datastream
Printer
Paper web
CISScan Bars
– =
ControllerBox
Direct comparison of virtualimage to printed image
23
24 Check for missing pages, documents and jobs
Check for correct sequence (front-back verifi cation)
Check for duplicates/ incorrect pages, documents, jobs
Check for correct print direction
Tracking SolutionThe tracking system monitors ongoing production
in terms of completeness and accuracy. The
consistency of ongoing production is constantly
compared with the target data and missing pages
or duplicates are identifi ed. Defective products
can be automatically fed out of the production
workfl ow and missing documents reprinted,
thereby facilitating fully automatic operation
and rendering manual controls superfl uous.
Standardized interfaces enable communication
with superordinate systems (host cumputer) to
take place and support monitoring across mul-
tiple lines and even multiple production sites.
LOG
CONTROL FUNCTION
BASIC INTEGRITY CONTROL
CONTROL FUNCTION
PRODUCTION LOGGING
TRACKING FUNCTION
TRACKING
Line Controller
Control & Tracking Solutions
25
Basic Integrity Control
• Page sequence control within the document
• Document sequence control within the job
• Document completeness control
• Front to back matching
• 1-up and/or optional 2-up production handling
Options: Stop the line, stack separation
Production Logging Basic Integrity Control
• Simple logging of results from Basic Integrity Control
• Share logging with external system (File based)
Tracking Production Logging Basic Integrity Control
Site Manager, tracking server with full tracking scope
• Duplicates detection
• Missing documents detection
• Full production tracking
• Production reporting
• Reprints generation
Options: Stop the line, stack separation, dynamic rejects
Check for correct enclosures, covers etc.
Production Logging Document error reject Flawless end products ready for shipment
Cont
rol Fu
nctio
nsTr
ack
ing S
olu
tions
LOG
CONTROL FUNCTION
BASIC INTEGRITY CONTROL
CONTROL FUNCTION
BASIC INTEGRITY CONTROL
CONTROL FUNCTION
PRODUCTION LOGGING
CONTROL FUNCTION
BASIC INTEGRITY CONTROL
CONTROL FUNCTION
PRODUCTION LOGGING
TRACKING FUNCTION
TRACKING
Customer Host
Customer Host
Site Manager
Single Line Tracking Multi Line Tracking
Line Controllerwith integrated Site Manager
Web Inspection
Web Inspection
Line Controller
Line Controller
Line Controller
Line Controller
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Web Inspection WI8
Stacker LS8-30Buckle folder
Offset Separator SE
Overpass unit
Pharma package leafl ets from the rollWith the Hunkeler Generation 8, production from the roll to the
fi nished folded package leafl et. Different end formats up to 30 inch
format length (B2+ sheets) possible. As an option, single-sheet
stacks up to a height of 250 mm can be stacked or single sheets can
be fed to a folding unit via the sheet overpass. In the CS8 cutting
module, inkjet printer color bars can be cut out automatically
and the format length can be changed dynamically from sheet to
sheet (Dyna-Cut). In the offset separation unit, sheets can be offset
laterally in run at full speed.
With the optional Hunkeler web inspection system WI8, even
the smallest defects can be detected and automatically rejected.
Details on the pages web inspection and tracking solutions.
Integrated diverterOffset stacking Variable chip-outB2+ sheet stacks with LS8-3026
Technical Data* | Pharma package leafl ets from the roll
Max. roll diameter: 54” 1370 mm
Web width: 8” – 22.5” 203 – 571 mm
Production speed: up to 590 ft/min up to 180 m/min
Paper weights: Light weight paper up to:
27 lb offset/book (max. 110 lb cover) 40 gsm (max. 300 gsm)
Format length: 5“ – 30“ 127 – 762 mm
Variable chip-out: 1/4“ – 2“ 6.3 – 50 mm
Options: Dyna-Cut, Tracking, Longitudinal perforation, Folding machine
Special Solutions
Unwinder
UW8
Length- and Cross
Cutter CS8
Web-Cleaning PEM
The paper dedusting unit iPEM and PEM removes the paper dust which adheres to the
paper-web and which would also foul the follow-on machines and digital printer. It works
with compressed air. The micro particles are removed contact-free from the paperweb and
are then collected in the exhaust air bin. If the speed of the web is low, the laminar fl ow is
activated, which creates an optimal operation independent from the speed of the web. The
sharp air jet takes off the dust from the surface like a planer. The paperweb is cleaned on
both sides in one process.
Available as an option on the unwinder UW8 (iPEM) or stand-alone (PEM).
Compact suction unit, mobile with integrated fi lter device
The HKU 2000-N nonstop is equipped with a chopper for the extraction of paper waste
cut-offs and endless strips. All machines are compact, mobile, and operate entirely in a
negative pressure mode for the extraction and fi lter devices. The dust-laden air is cleaned
in the fi lter unit, then returned to the production room; dust and paper cuts-offs fall into the
large volume container below the suction unit. In order to avoid compromising the operating
process of the production machines, they are equipped with a slider system, which allows the
full material container to be emptied during operation.
The module is also available as HKU 2000-B without slider system.
Ideal suction unit for Hunkeler Gen8 cutting lines.
Compact suction unit with high suction power
The HKU 1250 compact suction unit can be used for small dust quantities as well as for the
suction of remaliner punching (confetti). The mobile suction and fi lter unit is characterised
by high suction power, high effi ciency, low energy demand and low operating noise.
Ideal suction unit for Hunkeler DP8 with fi le holes and PP6.
Connection to a central extraction system
The central extraction system collects the production waste material directly from the Hunkeler
cutting modules. As an option, the endless edge strips can be perfectly cut by a shredder for
transport in the piping system. The shredder is equipped with a communication interface for
connecting the central extraction system and the Hunkeler production line.
Further information for central extraction systems of the Hunkeler systems:
www.hunkelersysteme.com
Hunkeler supplementary solutions Web cleaning and paper waste extraction systems
Functionality
Airfl ow/ Negative Pressure Bernoulli Principle Bernoulli Principle Contactless suctioniPEM PEM
27
Reaching the summit together
www.hunkeler.ch | [email protected]
Hunkeler AGBahnhofstrasse 31CH-4806 Wikon
Phone: +41 62 745 61 61Fax: +41 62 745 62 [email protected]
Hunkeler Deutschland GmbHBergstrasse 15D-82024 Taufkirchen
Phone: +49 89 614 1590Fax: +49 89 612 [email protected]
Hunkeler Far East Ltd.Room 1001, East Town Bldg.41,Lockhart RoadWanchai, Hong KongPhone: +852 2528 4082Fax: +852 2866 [email protected]
Digital: developed to meet specifi c needs: Solutions from Hunkeler
for pre- and post-digital printing are available for almost any imaginable
application. Publishing applications for small to medium runs, computer centers,
transactional and transpromo, security printing or creative direct mailing: we
have high quality solutions for all of these applications. A small sample of the
larger range of our potential end products are shown in this brochure.
Validated with all major printing presses.
*All solutions and technical data subject to change. Performance depends on
running confi guration, application, and substrates (paper).
Technical data will change with different running confi gurations like
bypassing a module, different non Hunkeler post-fi nishing solutions, etc.
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