Rationalisation in Perfection

At the printing plant Berger in Horn / Austria the
Roboload – a system for automatic jogger loading
from Schneider Senator – is responsible for a considerable higher efficiency in paper processing. Additionally, the working place is clearly enhanced.

It is a mixture of a consequent market and customer orientation and the continuous increase of efficiency in the whole production string, with which the head of printing plant Berger managed to held the company on course despite of economically difficult environment. With their slogan „The personal printer“ the company points up their proximity to the customer. This reflects in a higher customer loyalty compared to the branch average. Berger implemented a CRM software to improve the handling of the market and to simplify the designation of single customer segments. Followed by extensive controlling sales activities are reviewed and assure that the required profit margin is achieved. The controlling department therefore provides valuable information for the sales policy and even shows optimizing potential within the production chain.

„Our suppliers need to deliver promises“

With this background the management currently analyses all processes and is looking for possibilities to increase efficiency, in doing so Berger follows a very pragmatic approach for all kinds of investments. „We face the mentioned performance parameter of a solution and calculate which raising efficiency therewith is realistic for us. The suppliers need to deliver promises and during the realisation of the investment we stipulate the raising performance and efficiency parameter we have planned to achieve“, describes the director, Ferdinand Berger jun. „We can not afford that an investment does not meet our expectations in consideration of raising efficiency.“

The company produces over 300 magazines, approximately half of it is published monthly. The production emphasis are consisting books, catalogues and other job printing kinds. In doing so no job is too big or too small for the company – for example the highest-circulated Austrian magazine „Auto Touring“ with 1,3 Mio. copies is printed in Horn. Berger is always able to offer optimal and first of all economical solutions by using web offset printing and sheet offset printing as well as digital printing - whatever circulation and extent may be.



Take all opportunities

Over the past years Berger took all opportunities in raising efficiency. The management identifies potential in the area of cutting, and especially at the loading of the jogger.

There are only a few solutions to automate this production step within a cutting system. Strictly speaking there are only two solutions in the market which the management of Berger examined carefully on drupa 2008. At Schneider Senator’s booth the visitors viewed the fully automated jogger loading in a practical demonstration, in which Ferdinand Berger jun. pointed out that Schneider Senator tracks the most credible proposal.

The Austrian sales and service company Druma, Innsbruck, had been involved from the beginning and had taken over the technical project management in close contact with Schneider Senator.

Automatic detection of the position
The Roboload transports up to 45 000 sheets with a grammage of 80 g/sqm per hour fully automated without any intervention of the operator. The robot is an approved industrial robot, for which Schneider Senator developed a gripper and a laser measurement system. Formats from 430 x 610 mm up to
759 x 1050 mm in grammages from 80 up to 300 g/sqm can be processed without any problems. The engineers of Schneider Senator managed to copy the biomechanical movements for jogger loading to the robot.

The function that convinced Ferdinand Berger directly was the automatic detection of the position of pallet and reams. This relieved the application of the robot in practise extraordinary, comments Ferdinand Berger jun. Before Roboload can start to load the jogger, the integrated laser measurement system detects position, height and format of the paper pile. The gripper separated the ream at one corner in the preselected height up to 25 millimetres, grabs it up diagonally at two points and picks it up from the pallet. Afterwards the ream is ventilated, transported to the jogger and exactly deposited there. The sheets attain from the jogger over to the rear table of the cutting machine S-Line 137 CT by the sheet transport system BTS from Schneider Senator. Only now the operator starts his work at the cutting system, supported by CIP4-generated cutting programmes. Four buffer places care for continuous supply of reams for converting.



Economic efficiency grows with the number of cuts

At this stage Ferdinand Berger jun. points out that efficiency of the solution grows with the number of cuts. Basically after a short period of time it appeared that at the end of every shift even more converted paper lays on the pallet and the Roboload squarely meets the expectations. According to the appreciation of the director, in this solution there is still potential, which one wants to tap together with Schneider Senator by optimizing the cutting software. The relief of the employees by the Roboload going along with the upvaluation of the workplace is positively valued. „Beside the raising of efficiency the automatic jogger loading even released an excess of motivation, and our employees do not want to pass on the support of the robot“, underlined Ferdinand Berger jun.

Automatic jogging is more efficient than automatic cutting

In regard to automation of cutting systems the user needs to answer the question where to put the lever: The market offers solutions for automated jogger loading as well as systems for automated 4-side trim. In practice, the automatic jogging has a decisive advantage: The operator can concentrate on his basic job, the resulting buffer times can be used in a better way. If you cut automatically, the operator can load the jogger in the meantime but he needs to return to the cutter after approx. 90 seconds to continue his work. So the workload is rising instead of reducing. When Roboload is in operation the user however concentrates on cutting and unloading – the increase in productivity at a low physical strain is suitably high.


For any inqueries please contact:
Mr. Christian Behn
Sales Manager
Tel.: +49 (0)40-769159-23

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