Through selective main product feeding, the FlexLiner provides customers with entirely new opportunities to set themselves apart. Using up to three feeding positions, which can be fed manually, from the FlexiRoll buffer system or directly from the web printing press, inserts can be placed as FlexAds on the front or back pages of a main product, in addition to normal insert production. Thanks to their prominent position, each FlexAd stands out from the mass of inserts and provides customers with considerably greater advertising impact than traditional inserts.

Prominent Card Tipping

The card gluer unveiled at the IFRA Expo 2012 can now be integrated with the main jacket feeding. It affixes cards, inserts and flyers precisely to the front or back pages of the main product. The position of the card can be individually adjusted in accordance with the main product to achieve the greatest possible advertising impact.

Optimized Logistics

Several main products can be processed on the FlexLiner using the co-mailing procedure. The inserting system can produce different titles even at high speeds of up to 30,000 cycles per hour at very short intervals and for all quantities. They can then be reliably bundled in an optional sequence adjusted to the requirements of regionalization and zoning, for example using the FlexPack stack formation system, and distributed.

High Degree of Size Variability

With the FlexLiner, production can be covered by just one machine across the whole size range from a maximum of 420 x 300 mm to a minimum of 240 x 170 mm. To ensure quick and flexible production changeovers, all settings of the inserting system are adjusted fully automatically to the new sizes when there is a main product change. Both the bottom of the pocket and the lateral alignment adjust to the size defined in the commander, removing the need for manual settings. Fine adjustments can be made easily while the machine is running.

Simple Operation and Maintenance

Large Plexiglas panes enable optimal accessibility at the gathering sections and the inserting wheel. Feeding and running of both the inserts and the main product can be directly tracked visually and intervention is possible at any time, which massively increases production efficiency. Since the large doors can be simply and fully opened, the time spent on maintenance can be reduced considerably, for example when cleaning away paper dust, which accumulates at high production speeds and with high print runs. The feeder can simply be tipped by 90 degrees upwards for specific maintenance work, instead of having to be dismounted.

The FlexLiner also has remote capability. Through the MMRemote service module, Muller Martini can perform distance maintenance online from the factory, thereby keeping maintenance and service costs extremely low.

Flexibility thanks to Modular System Concept

The FlexLiner with up to 30,000 cycles per hour is the ideal inserting system for relatively small and medium-sized newspaper companies. It can handle print runs of up to 100,000 extremely efficiently thanks to its high production speeds. The flexibility and cost-effective operation of the FlexLiner also make it the right choice for advertising journals or mailshot packages with print runs of up to one million. It can be expanded in any number of ways thanks to its open system architecture. If production requirements change, immediate action can be taken. The FlexLiner can be expanded to have up to 30 feeding stations. These can be fed manually or using stream feeders as required.

Additional possibilities are created by individual addressing in the delivery transporter and the integration of a labeling system. The FlexLiner is equipped with both low folio lap opening and suction opening as standard. It is possible to switch simply between the two opening types, removing the need for additional investments in supplementary modules, which would otherwise be necessary. The time for both changeovers and fine adjustments is reduced to a minimum.

Cost-Effective Zone Production with MPC

With the trend for greater regionalization, more inserts and additional titles for external publishing companies, production sequences in the mailroom are becoming increasingly complex. The FlexLiner system from Muller Martini satisfies all complex mailroom requirements. The Mailroom Production Control (MPC) system connects all sub-processes and supports optimal workflow and thus the cost-effective use of the equipment in the mailroom. MPC coordinates the feeder allocation at the FlexLiner and supports the operating personnel in the correct assembly of products.