15,000 Inserts per Hour
Inserter driven by BRECOFLEX® StandardPlus polyurethane timing belts.
Inserts in newspapers and magazines have become a part of everyday life for readers. But hardly anyone knows how they get there. Most likely, the Swiss group of machine manufacturers, Müller Martini AG/Zofingen, is somehow involved there, since they and their more than 4,000 employees enjoy the very best reputation in the world of newspaper and magazine manufacterers as well as mail-order companies. "Alphaliner" is the name of the MM bestseller, an automatic inserter, which was developed by the subsidiary, Müller Martini Versand-Systeme AG/Zofingen (Müller Martini Mail-Order Systems PLC) and has been successfully built for over ten years now, this highly complex system transports the inserts on precisely coordinated and synchronously running rollers driven by a BRECOFLEX® StandardPlus polyurethane timing belt.
It is predominantly American newspaper and magazine publishers that count on the Alphaliner from Müller Martini. The company belongs to the worldwide leading manufacturers of print finishing and distribution systems. In the case of this machine, the often quoted comparison with a Swiss watch that “runs like clockwork” is for once truly appropriate: the polyurethane timing belt from Germany, as a main component of the drive, “runs” just as precise and reliable.
Successful all around the world with newspaper and magazine publishers as well as mail-order companies: the "Alphaliner" inserter.
Modular Design
The machine modular design allows customized configurations. The main product feeder is the basic unit of the "Alphaliner" and is manually or automatically provided with the main sheet. Up to 120 possible inserts are supplied by manual feeders, known as insert feeders, which are composed of two or four elements. Each element can take up to 4 inserts. These elements are driven by the BRECOFLEX® StandardPlus timing belt, which in turn, is driven by a central cardan shaft via a technically complex return pulley system.
The functionality and technology of the "Alphaliner" is convincing: the main product newspaper, magazine or catalogue is opened by a gripper fold or suction cup and held on both sides while the insert shoots in. A quality control station automatically reject discharges incomplete products. The removal conveyor grips the main product on the open top side, thus, ensuring that the inserts cannot fall out.
The bare numbers are impressive: the main product can measure a maximum of 430 x 310 mm and for magazines be up to 240 pages thick. The maximum number of pages of the inserts to be inserted is 96, which is equivalent to a thickness of up to 6 mm. At peak, an Alphaliner can insert up to 15,000 copies per hour.
The BRECOFLEX® StandardPlus transfers the power from the cardan shaft to the insert feeders by way of this return pulley system.
High forces paired with high reverse bend strength
The extremely complex inserter with its many transport shafts and rollers must be driven by timing belts in a completely precise and synchronized manner. The solution: the BRECOFLEX® StandardPlus is 4,250 mm long for the Alphaliner equipped with two feeders and 6,000 mm long when four feeders are installed. The decision was made in its favour, among other reasons, because it can transmit high forces at a high reverse bending strength with a small length extension.
In the Alphaliner the timing belt passes various synchronizing pulleys and rollers and also convinces technically by its capability of driving the control pulley of the insert feeder with its almost 350 mm diameter due to its pitch precision paired with a large meshing angle. This is extremely important for an accurate supply of the various inserts. Since the inserts are diverted across horizontal and vertical axles a number of times, it is vital to also take the high requirements on a guided straight run and the changing torsional load on the belt bodies into account.
Manual supply of the insert feader.
Precision: The most important topic
"Achieving the highest degree of precision", according to Andreas Baumann, the team leader of the insertion division at Müller Martini Versand-Systeme AG, "is the greatest challenge for the drive of our Alphaliner“. He praises the new generation of BRECOFLEX® StandardPlus timing belts, which offer precisely that, in fact their "high precision“ allows them to be compared to moulded timing belts. Extensive trials have revealed that the bifilar tension member winding of the new generation of timing belts has extremely minimized the run-off tendency of the belt.
Due to its flexibility, reliability and modular individuality, the Alphaliner inserter from Müller Martini is still quite in demand worldwide even after a ten year construction period. And the "upgrade" of the drive through the new BRECOFLEX® StandardPlus polyurethane timing belts should boost demand even more, as the precision of the system is even further improved. The significant modifications in production technology of BRECO, the Mulco partner, regarding the consistency of the tooth spacing within the timing belt can be seen here in the example of the machine. The lateral run-off force of the timing belt, which has been reduced to virtually zero, maximizes the accuracy while minimizing frictional loss.
The BRECOFLEX® StandardPlus with 25 mm width and special tension cords made of high-tensile strength, flexible E 9/15 steel cords is used in the Alphaliner in customer-specific lengths of 4,250 mm and 6,000 mm. It is predestined for such applications especially due to its great flexural strength, the high mechanical strength and stiffness, minimal extension under high stress and 98% efficiency as well as wear resistance and ageing stability when applied in continuous operation.
On the whole, the BRECOFLEX® StandardPlus unites all of its previous advantages in one new optimization:
Highest level of precision with synchronous motion transmission.
High degree of wear and consistency of length.
Repeat positioning accuracy.
Pitch precision rotational to linear translation of movement.
Maintenance-free operation.
Resistant to hydrolysis, ozone and sunlight.
Temperature resistant from – 30c C to + 80c C, higher for short periods of time.
Resistant to petrol, simple fats and oils.
Silicone-free production.
Hanover, February 2006
Mulco-Europe EWIV