At ISA Sign Expo 2016, Esko showed highly automated digital finishing systems that can convert large-format graphics into signs, creative displays, and packaging. The systems include software features that can make sign shops more productive and profitable.
According to John Giardina, president, Esko Americas, the integrated end-to-end systems can help businesses large and small.
Automated Digital Finishing Systems
Esko showcased two models from its Kongsberg family of digital finishing systems.
The Kongsberg C64 is a state-of-the-art superwide (126 x 126 in.) digital finisher. Its unique carbon composite transverse beam supports the precision and productivity required to cut printed graphics that over 10 feet wide. The Kongsberg C64 is the only superwide finisher with a continuous-duty high-performance milling unit.
At ISA Sign Expo, the Kongsberg C64 was demonstrated with an automated system that feeds printed or blank boards onto the cutting table. Material is loaded with a fork truck or pallet jack—in either portrait or landscape mode. The Kongsberg C64 can also be equipped with an optional roll feeder.
To see the different types of finishing processes that the Kongsberg can handle, with this video: YouTube: Esko Kongsberg C Cutting and Milling a Range of Materials
The Kongsberg XN is built for versatility. Its wide range of specialty tools can be used to cut and mill many types of materials, including vinyl, corrugated, folding carton, foamboards, solid boards, wood, and a long list of plastics.
It comes with industry standard print-to-cut registration, a camera system for vision cutting, and many other features. The Kongsberg XN24 shown in the Sign Expo booth will be 66 x 126 inches. The XN product family is available in seven different sizes from 66 x 50 inches to 87 x 258 inches.
i-cut Production Console
The i-cut Production Console (iPC) drives all of the functions of the Kongsberg table, including camera control, machine set up, tool recognition, calibration, and tool adjustments.
Esko recently announced new features to the front-end operating system that will make production planning for digital finishing operations easier to manage. The new features makes it more efficient to run a higher number of short run jobs.
With the integration of a complete materials database, Esko has bundled decades of digital finishing expertise into a system that can take some of the guesswork out job set-up. The system advises the operator on which tools and knives to select for the type of materials to be finished on the next job. This advice can reduce the changeover time between jobs, improve consistency over time, and lessen the risk of damaging expensive materials.
Esko has also integrated its Kongsberg tables with its workflow automation software, Automation Engine.
Automation Engine’s Device Manager gives better control over finishing production. On the display screen, the operator can clearly see the status of work in progress and queues of all connected devices. The software determines optimal sheet nesting to increase production capacity. Operators use an intuitive drag-and-drop interface to prioritize table queues, insert rush jobs, and even balance workloads between tables.
The new Kongsberg Estimating module can give business owners a more accurate estimate of how long each job will take to produce. This is important when preparing quotes for customers — particularly in an environment in which the margins on short run digital print work are tightening. With accurate job estimates, companies can communicate better quotes and forecast more accurate delivery times to their customers.
The new Kongsberg Estimating Software module generates production estimates automatically based on production metadata such as the substrate type and thickness of materials specified in designs for packaging, signage, and display jobs.
Esko’s i-cut Suite is a collection of prepress and pre-production software solutions. The i-cut Suite helps eliminate errors, save time, and reduce waste by automating tasks such as preflighting and editing design files, nesting graphics, and setting up cutting paths.
Esko ArtiosCAD and Studio software supports the 3D design of displays made from rigid sheets. Dedicated tools streamline structural design, graphic development, virtual prototyping, and manufacturing of the approved designs.
Automation Engine isn’t just for finishing operations. It can also serve as the heart of prepress production and manage workflows that are constantly being updated or rescheduled. Automation Engine can also be set up for automated color management on multiple types of printers.
Esko believes all of their innovative and scalable workflow and finishing solutions can empower sign and display companies to attract new business. Their newest workflow improvements are designed to take digital finishing efficiency and simplicity to the next level.