Sattler Premium Print GmbH puts its trust in Heidelberg

Complete system comprising Speedmaster XL 106, Stahlfolder TH 82-P, P-Stacker, and Polar PACE cutting system

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Sattler Media
After the contract signing, from left - Martin Koschei, managing partner, Sattler Media Group GmbH, Marco Dankert, head of Technical Operations, Sattler Premium Print GmbH, Martin Wilke, sales account manager, Heidelberger Druckmaschinen Vertrieb Deutschland GmbH, Stefan Kuper, head of Region North, Heidelberger Druckmaschinen Vertrieb Deutschland GmbH, Ralf Büttner, managing director Technology + Organization, Sattler Media Group GmbH.

Sattler Media Group GmbH has over 500 employees working at four production sites in Germany – Bad Oeynhausen, Hildesheim, Hornburg, and Magdeburg. The company uses sheetfed offset, web offset, and digital printing technologies to manufacture catalogs, magazines, mailshots, and newspaper supplements, describing itself as a strong partner for all aspects of cross-media dialog marketing. It supplies print products to food retailers, publishing houses, furniture manufacturers, the tourism industry, and insurance companies.

Sattler Premium Print GmbH, which is based in Bad Oeynhausen, has been part of Sattler Media Group GmbH since November 2020. This is where the Group has concentrated its sheetfed offset printing portfolio. With a view to boosting its performance and competitiveness, the company has now invested in the very latest production technology, thereby modernizing its entire sheetfed offset printing process, from the cut sheet through the actual printing process to signatures that are palletized on a fully automated basis.

Heidelberg
Sattler Premium Print GmbH, part of Sattler Media Group GmbH, is based in Bad Oeynhausen, approximately 40 kilometers northeast of the city of Bielefeld.

This major order went to Heidelberger Druckmaschinen AG (Heidelberg). It includes an eight-color Speedmaster XL 106-8-P+L perfecting press of the latest generation, an all-buckle high-performance Stahlfolder TH 82-P folding machine with PFX feeder and P-Stacker, and a Polar N 137 PACE cutting system with Autotrim, rear table loading, and automatic rotation (PACE stands for Polar Automation for Cutting Efficiency). The new machines are to be commissioned between April and July 2022.

Fully automated from the flat sheet through to the palletized signature

“The aim of the investment is to significantly increase production output without changing staffing levels,” explains Ralf Büttner, managing director Technology + Organization at Sattler Media Group. “By this summer, thanks to technology from Heidelberg, we will have largely automated our entire process from the unprinted flat sheet through the folding process to the palletized signature.” To achieve this, Sattler Premium Print will integrate the sheetfed offset, cutting, and folding technology into a digital workflow control system. Any information that will help maximize speed in an automated setup process is transferred to the production systems from the prepress stage. This also includes data from the imposition software for fully automated calculation of the cutting programs on the Polar PACE system.

Stahlfolder TH 82-P carries forward peak performance

Büttner expects the Stahlfolder TH 82-P folding machine to considerably speed up production, too. The PFX feeder introduces the flat sheets into the folding system shingled, which will help Sattler Premium Print achieve a folding output of up to 18,000 sheets per hour. This will mean the Stahlfolder TH 82-P can keep pace with production on the Speedmaster XL 106, so that the peak performance in sheetfed offset printing can be carried seamlessly through to postpress. A P-Stacker installed at the output of the folding machine will take the stacks of signatures and automatically set them down on pallets. Besides safeguarding excellent process stability at high speeds, the robot also takes care of heavy physical work that would otherwise be left to staff. This means employees can apply their skills to other production tasks instead. “We scoured the market very carefully and considered various options,” recalls Büttner. “Ultimately, Heidelberg won us over with its complete, highly automated system, which covers the process chain from end to end with coordinated components.”

As part of a service contract, Sattler Premium Print has locked in service and maintenance work for a period of 24 months, which can be extended to a further 48 months. The contract also covers regular software updates on the Prinect Press Center XL 3, the control station of the Speedmaster XL 106.

Investment activity on the rise

The decision made by Sattler Premium Print GmbH to invest in the latest high-performance technology is a good example of the positive outlook that has returned to the printing industry in Germany. Over the past two years, the sector has held back somewhat, but printing companies are now increasingly looking to update their technology and invest in state-of-the-art production systems. David Schmedding, managing director of Heidelberger Druckmaschinen Vertrieb Deutschland GmbH, believes developments are moving in the right direction, “We are starting to see an uptick in investment activity across all markets and regions. The sales we have made in the past few months are cause for optimism and show that Heidelberg is on the right track with its innovative solutions supported by a consistent digitalization strategy.”

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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