HEIDELBERG INDIA

EDITION 4 ISSUE 1
EDGESPEAK
O b s e s s e d w i t h p r e c i s i o n - j u s t l i ke yo u .

POLAR in the News Online Training Program Product Feature

Tips and Tricks Did You Know? Contact Details

Dear Print Industry Colleague,

We're pleased to bring you the 4th edition of POLAR EdgeSpeak. POLAR has seen two more special
achievements in 2009. The POLAR L-R-137-T PACE cutter has set a productivity record of 6 pallets per hour!
Also, POLAR has been ranked the No. 1 postpress firm in a survey. This has been a great ending to 2009 for
POLAR and has spurred it to take even greater strides with the year ahead.
The Product Feature section talks about the Jogging System L-R-P, Cutting System L-R-P-T and the Label
Systems DC-11, SC-20 & SC-21. The Tips and Tricks section explains the Align Material function, which
enables automatic realignment of cutting material.
We look forward to your feedback & queries. And warm New Year wishes from all of us. May 2010 bring you
plenty of happiness and success.
Mr. Saseendran
Product Manager, POLAR Equipments

POLAR and Heidelberg celebrate 60 years of partnership

POLAR IN THE NEWS
A family friendship led to global market leadership

During the monetary reform in 1948 and the foundation of the Federal
Republic of Germany in 1949, Germany amazed the world with what was
considered an economic miracle. All over the country, people were building,
planning and investing, including those in the printing industry. Nicolaus
Reisinger, the head of the Heidelberg sales office at the time & the Mohr family
were friends; and this friendship expanded into business relations.

Both companies were exhibiting their products together at the 1949

A present is handed over to commemorate
60 years of business partnership.
From left to right: Alfred Henschel – Joint
Managing Director, POLAR, Bernhard
Schreier – Chairman of the Board at
Heidelberg and Michael Neugart – Joint
Managing Director, POLAR.
Frankfurt Spring Fair, where Hubert Sternberg, the Director of Heidelberg at
the time, came to know about the Hofheim-based company. He was
impressed by the technology and wide range of functions of the cutting
machines. Sternberg intended to complement his range of products and had
been looking for a supplier of cutting machines for the Schnellpressenfabrik
Heidelberg (Heidelberg high-speed presses factory). He recommended that
the brothers Rudolf and Karl Mohr collaborate and use the sales partners
together worldwide.

Now, the companies are celebrating 60 years of successful partnership!

Over the decades, both companies have grown and become world market
leaders. POLAR has sold more than 130,000 high-speed cutters through the
distributive channels of Heidelberger Druckmaschinen AG.

POLAR felt that this was the perfect occasion to thank Heidelberg for the long
lasting partnership and expressed its gratitude to Bernhard Schreier,
Chairman of the Management Board of the company. Alfred Henschel
summarised the mutual relation in one sentence: “This connection, which is
based on partnership and friendship, is an economic success story we are
always enjoying...”

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POLAR cutter sets efficiency record

A POLAR automatic cutter with only one operator achieved productivity

of more than six pallets per hour!

Last year, POLAR's L-R-137-T PACE system won the globally respected
PIA/GATF InterTech™ Technology Award in the USA. During POLAR
Technology Days 2009, this system, operated by only one person, processed a
record 43 reams in an hour – more than 6 pallets, each one metre high!

The paper was manually prepared in a jogger and then automatically loaded
through a buffer onto the rear table. Here, the material was trimmed on all
four sides and finally stacked on pallets, both through automatic processes.
Marketing Director Rolf Brand is pleased
with the excellent result.
Not only is the L-R-137-T PACE cutter very fast, but it has a compact
design as well, not taking up much more space than a standard system.
The cutter is also very flexible - small runs and a wide variety of materials can
be processed.

Michael Neugart, Managing Director of POLAR says: “With this level of

efficiency we can frankly claim to be offering the world's fastest cutting
system. A cycle time in four-side trim of well under 90 seconds per ream!
We'd really like to see anyone else do that.”

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POLAR ranked No. 1 postpress firm in a survey

A 2009 customer survey about service quality in the graphic arts industry
conducted by Hamburg-based management consultancy Apenberg und
Partner ranked POLAR as the No. 1 postpress firm among nineteen suppliers in
the industry.

The relevant study examined three areas – regular maintenance work,

non-scheduled repair work and extraordinary services. Overall, POLAR was
placed third – behind Heidelberger Druckmaschinen AG and Océ.

For Michael Neugart, the Managing Director, this is a clear confirmation:

After the safety check, the machine gets
its test badge.
“We know that fast and reliable service minimises downtimes and saves cost.
Therefore, we have been doing our homework in the field of service in the past
years together with our business partner Heidelberg. The result of this survey
confirms our efforts. As far as the small and medium enterprises are
concerned, our service centre certainly ranges among the top 10 worldwide.
In 2006, we invested over 5 million Euros in this modern logistics centre in
order to ensure we will still be keeping our promise of a 25 year availability of
service parts in future. In the meantime, we have been reaching fantastic
values with parts availability of 96% and up to 94% of all orders being
shipped on the same day. A major factor is that all the ordering processes of
our sales partner Heidelberg are integrated into our own systems. This
safeguards minimum reaction times. POLAR also applies a high standard in
the training of our service technicians around the world. Year after year we are
training up to 500 engineers in sessions of over 2,000 man-days to ensure
utmost service quality.”

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Online interactive training for using high-speed cutters

ONLINE INTERACTIVE TRAINING

POLAR has an online interactive training program for operation of high-speed

cutters. The program has been conceived in close co-operation between
POLAR and the Bundesverband Druck und Medien (BVDM) – the German
printing and media industry federation. The training program is of particular
interest for beginners in the field of cutting - new machine operating staff,
students, apprentices and trainees.

The training is highly simplified. It focuses on peripheral units, interlinking,

cutting formats and sequences. The exercises guide the user through a
step-by-step process – there are varying levels which help him proceed
from easy to difficult cutting operations. There is also a glossary for
immediate reference.

Visit the POLAR website to view the program and its features. It is sure to
promote better learning among your employees.

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Label System DC-11

PRODUCT FEATURE
The automated Label System DC-11 enables much faster and efficient
inline production of bundled die-cut labels. It guarantees superior
performance – of up to 960 bundles per 60 minutes, among other
advantages. The menu-driven setup makes operation easier and reduces
make-ready time. The label system is equipped with an Autocut 25 cutting
machine, a DC system die-cutter and a single head bander.

Customer Benefits

Can cut up to 960 bundles per hour with minimum manpower.

l
Label System DC-11
OptiChange
l allows the operator to perform a job change in only
15 minutes.

OnePunchRegister
l allows positioning of the cutting die in line with
the printed image with just one punch of a button.

Utmost cutting and die-cutting precision.

l

High reliability in daily use, and a longer lifespan.

l

Automatic Cutting Machine Autocut 25

Front
l side knife change with alternate frames allows preparation of
the knife outside the machine.

Lateral
l aligning gauge, front gauge system and waste cut aligning
gauge ensure high quality output.

DC System Die-cutter

Alternate
l frame system (patented) with a positioning aid for
preparation of the knife outside the machine.

A centred
l alternate frame (patented) allows precise alignment to the
right and left hand sides.

Size
l adjustment of the gauge and feeder without any tools via a
hand wheel (patented).

The
l stamping punch can be continuously extended millimeter by
millimeter for setting the register.

Optional:
l Cardboard remover (patented) allows the operator to work
with underlay cartons even for log banding.

Optional: Manual feeding of the die-cutter.

l

Single-head Bander

Motorised format adjustment via a central control display.

l

Precision
l adjustment is carried out in case of automatic operation
as well.

Allows
l two separating processes per die-cutting cycle, if the pack
contains two divider cartons.

Ultrasonic welding unit for single pack and log banding.

l

Direct
l restart of production after interruption of control voltage, e.g.,
after hitting a light barrier.

Technical Data

Label size (min.)¹ 20 × 40 mm | 0.79 × 1.57 in

Label size (max.) 170 × 210 mm | 6.69 × 8.27 in

Stack height (min.) 35 mm | 1.38 in

Stack height (max.) 120 mm | 4.72 in

Height of cutting die (min.) 50 mm | 1.97 in

Height of cutting die (max.) 100 mm | 3.94 in

Performance (max.)² 16 cycles / minute

Benchmarking DC-M DC-11

Number of operators 2|2 1|1
Bundles / 60 minutes 480² 960³

¹ Depending on stack height. | ² Depending on material, label size, operator. | ³ Depending on

material, label size, pre-cutting, strip changes.

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Label System SC-20

The Label System SC-20 is ideal for high automatic inline production
of square-cut labels with integrated banding. It has an excellent output rate –
of up to 1,296 bundles in 60 minutes. It's equipped with an Autotrim M cutting
machine and a BM-105 multi-station bander.

Customer Benefits

Performance
l of up to 1,296 bundles per hour with minimum
manpower.

Greatest
l cutting accuracy due to the POLAR Positioning System DPS
with a mechanical positioning accuracy of 1/100 mm.

Very flexible, thanks to easy and fast conversion.

l

High long-term reliability.

l

Automatic Cutting Machine Autotrim M

Downholder in front of the knife.

l

A lateral
l aligning gauge at the frame and backgauge further improves
the cutting quality, because strips can be precisely aligned.

Mobile
l aligning station (patented) on the front table for aligning the
cut labels.

Optimised
l lateral de-loading finger for smooth workflow and faster
cycles.

Multi-station Bander BM-105

Electronic
l temperature control monitors and optimises the welding
process.

Full-surface
l row pusher with frequency-controlled drive for smooth,
trouble free workflow, and automatic speed control depending
on the format.

A movable
l table board (patented) closes the lower gap and ensures
that the label row is perfectly pushed in. Its integrated sensor scans
the format and automatically controls the pressure feet of the
banding unit.

Easy
l adjustment of cassette holders, because the upper and lower
ones can be adjusted simultaneously (patented).

Technical Data

Label size (min.)¹ 20 × 43 mm | 0.79 × 1.69 in

Label size (max.) 230 × 1,050 mm | 9.06 × 41.34 in

Cutting width in automatic mode (max.) 1,050 mm | 41.34 in

Stack height (min.) 20 mm | 0.79 in

Stack height (max.) 120 mm | 4.72 in

Clamp pressure (min.) 150 daN

Clamp pressure (max.) 5,500 daN

Banding station (max.) 18

Performance (max.)² 4 cycles / minute

Benchmarking (bundles / 60 minutes) L-R-137-B³ SC-20³ SC-214 SC-254

Number of helpers / operators 2|1 1|1 1|1 1|1
24 labels / sheet (4×6, waste cuts) 308 314 890 —
96 labels / sheet (8×12, waste cuts) 635 712 2,044 855
192 labels / sheet (12×16, no waste cuts) 1,150 1,296 3,185 1,670

¹ depending on stack height. | ² depending on material, label size. | ³ including pre-cutting. |

4
excluding pre-cutting.

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Label System SC-21

The Label System SC-21 is highly suitable for automatic inline production of
square-cut labels with integrated banding. It has a superior performance rate
of up to 3,185 bundles per hour - offering efficiency increased by 25% to
five cycles / minute. The label system equipment includes an Autocut 115 and
a multi-station bander BM-105 - similar to the SC-20.

Customer Benefits

Performance
l of up to 3,185 bundles per 60 minutes with minimum
manpower.

Utmost cutting precision due to the lateral and front gauges.

l

Very flexible, thanks to simple and quick conversion.

l

High reliability in daily use, and longer lifespan.

l

Advantages of the Automatic Cutting Machine Autocut 115

Fast loading due to 120 cm/sec return speed of the backgauge.

l

A lateral
l aligning gauge at the backgauge further improves the
cutting quality, because strips can be precisely aligned against the
backgauge.

Aligning
l station (patented) on the front table for aligning the cut
labels.

Optimised
l lateral de-loading finger for a smooth workflow and faster
cycles.

Technical Data

Label size (min.)¹ 20 × 43 mm | 0.79 × 1.69 in

Label size (max.) 230 × 1,010 mm | 9.06 × 39.76 in

Stack height (min.) 30 mm | 1.18 in

Stack height (max.) 120 mm | 4.72 in

Banding station (max.) 18

Performance (max.)² 5 cycles / minute

Benchmarking (bundles / 60 minutes) L-R-137-B³ SC-20³ SC-214 SC-254

Number of helpers / operators 2|1 1|1 1|1 1|1
24 labels / sheet (4×6, waste cuts) 308 314 890 —
96 labels / sheet (8×12, waste cuts) 635 712 2,044 855
192 labels / sheet (12×16, no waste cuts) 1,150 1,296 3,185 1,670

¹ depending on stack height. | ² depending on material, label size. | ³ including pre-cutting. |

4
excluding pre-cutting.

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"Align Material" function allows automatic paper alignment

TIPS & TRICKS
After every cut, the material in front of the knife is shifted forward and has to
be manually realigned. Usually, the operator will lock the backgauge in place
Benefits
by pressing the pedal of the clamp after cutting. Then he can align the
Makes
n alignment of
the material after material which has been shifted and is lying in front of the knife against the
cutting easier. other material which is locked under the clamp. However, since he has to
Improves ergonomics
n
keep pressing the pedal, his freedom of movement is extremely limited.
by increasing the The function "Align Material" is an ideal solution.
freedom of movement.
“Align Material” is an automated function. After the cut, the clamp remains
positioned on the material for a preset time, which allows a convenient
alignment. Once the time period has elapsed, the backgauge drive is
automatically started, provided that the light barrier has not been obstructed.

In Autotrim models, the function facilitates alignment of the cutting material

against the upright table flap. The table flap is in line with the front table
gauges and helps to push the material easily to the side.

Adjustable timers:

Timers 1-8 (0.5 – 6.5 sec)

l

Timer 9 (backgauge drive has to be started manually)

l

Availability
X XT Autotrim
— 78 - 176 115 - 176

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Did you know?

Die-cutting originated during the industrial revolution. The process
has been used right from the mid 1800s.

Sales Support: Mr. Saseendran, saseendran.baskaran@heidelberg.com

Marketing Support: Namrta Dhar, namrta.dhar@heidelberg.com

Contact Details

Service Support: A. Prabaharan, prabaharan.annamalaichami@heidelberg.com