At the Inca Digital site in Cambridge, UK, a unique set-up has been created to showcase the potential of automated production.

This combines an Inca Onset X HS printer and robotics with a Zund D3 L-3200 cutting table. The combination allows for the automated loading, printing and offloading of sheets, creating efficiencies and productivity gains when digitally printing sheets and boards.

Matt Brooks, head of products and solutions at Inca digital, explains, ‘We’ve been collaborating globally with Zund on a few individual projects that have involved the integration of the cutter.

‘These have all been successful as individual projects, so are now bringing together a formal global offering for both Zund and Inca customers, providing efficiency and increasing our customers’ capability and reach in terms of material handling and a full print-to-cut workflow.’

Key to this is the integration of robotics that have sped up the ability to load/offload sheets, and to flip sheets for double-sided printing. Robotic arms then allow printed sheets to be moved directly to a Zund cutting table, or offloaded and stacked, depending on the customer’s specific production environment and requirements of the job. This is monitored by print marks and an onboard camera system, which helps ensure accurate registration on both the printer and the cutting table. This effectively allows ‘lights out’ production, with the entire process automated. Further integration is also possible, allowing the system to plug into wider business workflows such as conveyors, etc.

Currently, the system can process sheets and corrugated board up to 3.2m in width, with a maximum weight of 5kg per 5 x 10ft sheet.

The system is customisable and can be configured to the needs of the converter, notes Mr Brooks, who says, ‘There are various options and configurations, which allow the system to be tailored to the customer’s requirements, output and workflow.’

Fujifilm and Inca Digital have now formally introduced robotic tools to further the scope and application range of the Onset X HS range of ultra-high productivity large format printers. Such automation technology assists with long run production, as well as reducing job changeover times and the need for manual intervention between runs.

This is aided by Zund’s cutting systems being based on a modular design concept, making them flexible and expandable, and configurable according to specific requirements.

Dean Ashworth, sales and marketing director at Zund UK, reiterates, ‘In the current climate and wider world, with the impact of Covid-19 and Brexit, we’re seeing more and more customers looking to improve their efficiency, achieve greater productivity, and deliver cost reduction. This is largely being achieved through minimising touchpoints and reducing overheads.

‘The feedback from the market has been that there is nothing else out there like this. It is the only demonstration facility globally. Nor is it ‘conceptual’. We have implemented similar set-ups in multiple manufacturing sites, largely in the US, but at Inca’s site in Cambridge we can demonstrate the full potential, both virtually and in-person in a Covid-safe and -secure environment.’

Packaging potential

Mr Brooks identifies the system as a ‘good use of the technology outside of automotive and food manufacturing’, where such a degree of automation is more prevalent.

It also showcases a high degree of material handling capability, with dual robots specifically noted as allowing a move beyond sign, graphics and display applications, into packaging applications such as corrugated.

‘E-commerce is a booming market, as we have all seen and experienced as a consequence of Covid-19. As a result, paperboard is on the up,’ says Mr Brooks. ‘With such a set-up, print providers can be creative and take a sheet and turn it into an attractive and personalised printed piece. Both sides of the sheet can now be printed more easily, enhancing the value of the output.’

Mr Ashworth adds, ‘The various components have worked together perfectly, and are now shown integrated to introduce a new paradigm in terms of a fully automated print-to-cut workflow solution. The robotics can of course be used for other processes, depending on the workflow. The system can be tailored, as the demo line is quite large and we are showcasing the full potential. Systems with a smaller footprint are available.’

Those wishing to book a demonstration can do so by contacting either salesuk@zund.com or marketing@incadigital.com.