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October 2-4, 2024, we hosted our Horizon Smart Factory event at our headquarters and factory in Takashima, Japan! The event included our partners and customers from all over the world, with over 400 attendees representing more than 25 different countries! In addition to our guests, we welcomed 15 printer vendors, workflow partners, and companies specializing in packaging and robotics.
Creating a one-of-a-kind experience was crucial during the planning of this event so we really got creative with system configuration, display, and presentation. The event was divided into three Zones: The Automation ＆ Workflow Zone, The New Focus Zone, and The Lights Out Zone. All zones focused on reducing touchpoints and manual labor, increasing efficiency and automation, and testing new technology and interfaces resulting in over 20 integrated end-to-end systems.
Keep reading for information on all three zones, specific systems, and event highlights.
Systems & Zone Highlights - Table of Contents
Click to Jump to Desired Section
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・Lights Out Experience
・AGV-Assisted Smart Binding System
・AGV-Assisted Saddle Stitching System
・Inline Web Press ＆ Smart Binding System
・Robotic Arm POD Book System
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・AGV Logistics Zone
・Workflow Zone
・SmartStacker ＆ Robotic Feed Smart Binding System
・Pressure Sealed Application System
・Inline Cut Sheet Press ＆ Sheet Processing System
・Inline Cut Sheet Press ＆ Rotary Die Cutting System
・Plow Fold Smart Binding System
・iCE STITCHLINER Mark V
・iCE STITCHLINER Mark IV
・Standalone Systems
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・Autopile and Jogging System
・B1 Folder and Robotic Palletizing
・MiniCABS ＆ Robotic Palletizing
・Pallet Wrapping System
・Flexible Package Processing ＆ Robotic Boxing System
LIGHTS OUT ZONE
The main attraction of HSF 2024 was our Lights Out Zone, where we made the dream of autonomous production a reality by designing systems that can operate in the dark without human intervention. This was achieved through the integration of printing and finishing equipment, robotics, and workflow technology.
This zone included our AGV Assisted Smart Binding Solution, AGV Assisted Saddle Stitching Solution, Inline Web Press and Smart Binding Solution, and Robotic Arm POD Book Production System.
Lights Out Experience
The highlight of this zone was the “Lights Out Experience”, an immersive guided journey through the future of print finishing. With the lights out, guests were invited to envision a production floor without any operators as our four end-to-end solutions produced applications autonomously. If you couldn't make the event, we’ve created a video version for you located above!
AGV-Assisted Smart Binding System
*Collaboration with Canon and RISO
Our AGV Assisted Smart Binding System produced both A5 and A4 books using two binders in a single system! The first line, AGV-Assisted Binder Line, starts with a Canon imagePress V900 press, printed materials are gathered from the delivery section of the printer and fed into the feeding section of our SmartSlitter sheet cutter and creaser via forklift AGV. The table raises up to start feeding sheets automatically, creating book blocks that are fed into our 4 clamp perfect binder, the iCE BINDER BQ-500, by a robotic arm.
The second line, Inline Press and Binder Line, begins by printing book-block pages on a RISO VALEZUS T2200 press which are delivered directly into a jogging station. From the jogging station, the book blocks are fed into our brand new iCE BINDER BQ-300 single clamp perfect binder by robotic arm.
Books from both systems meet at a traffic control conveyor that processes the books one by one and sends them to our 3-knife trimmer HT-1000V that can handle the capacity of both binders. After trimming, books coming from the RISO/BQ-300 are stacked in a finished pile and taken to the sample station by AMR. The Canon/BQ-500 books are packaged inline with Rengo’s eCommerce packaging machine and then automatically transported by AMR to the sample station.
AGV-Assisted Saddle Stitching System
*Collaboration with Canon and Konica Minolta
This system produced A4 booklets from press to pallet without the use of any human labor! Starting with two cut sheet presses, the Canon imagePress V1000 and Konica Minolta AccurioPress C14000, printed materials are picked up by AGVs and delivered to our brand new iCE STITCHLINER Mark V high speed sheet feeder, the HSF-50.
Once fed into the machine, the feeder rises and begins feeding the system sheets (up to 45,000 per hour for A4 format sheets and 35,000 for A3). The pages are then accumulated, stitched, and trimmed with the Mark V at speeds of up to 6,000 booklets per hour. The finished booklets are sent inline directly to Palamides banding and stacking unit, gamma 502ho, using an interface developed in collaboration between Horizon and Palamides. Finally, the banded booklet stacks are automatically palletized by a robotic arm and transported away by AGV.
Inline Web Press ＆ Smart Binding Solution
*Collaboration with SCREEN and Hunkeler
This system starts with a blank roll and ends with sorted book jobs! Roll unwinding occurs with the Hunkeler UW6 Unwinder before printing with SCREEN’s TruePress Jet520HD mono. From the printer, the paper passes through the Hunkeler Web Buffer WB8 and Sheet Cutter CS8 to produce cutsheets.
The imposition of the jobs is dynamic, switching between 12- and 8-page signatures to reduce blank pages and increase efficiency. Downstream devices can also handle this dynamic imposition, with dynamic cutting on the Hunkeler web processing technology and then dynamic folding in our AFV-566SF buckle buckle folder, which creates the signatures. Once signatures are created, they go to the BBS-40L Book Block Stacker, where they are accumulated and glued to become book blocks.
Next, book blocks are sent inline to our LBF-500 loose sheet book block feeder, which feeds them into our iCE BINDER BQ-500 4-clamp perfect binder for binding. The last step in creating the book is the final trimming with the HT-1000V variable three-knife trimmer.
This system features high-level quality control with multiple checkpoints that ensure no misprints, poorly folded signatures, missing signatures, and mismatching covers/book blocks occur, with lists of bad books created to know what’s needed for reprinting. Additionally, books are scanned after trimming and sorted by job into our box delivery system, when boxes are full, an AGV transports them to the next location and brings in new boxes.
Robotic Arm POD Book System
For the last system in our Lights Out Zone, we introduced our Robotic Arm POD Book System, which eliminates touchpoints through the use of a robotic arm and inline binding and trimming. Book blocks are printed on an offline press and delivered to our HOF-400 high speed offline feeder, which feeds the sheets directly onto a jogging station.
A robotic arm picks up the book blocks from the jogging station and feeds them into our brand new iCE BINDER BQ-300 single-clamp perfect binder. Bound books are then delivered to a conveyor and sent for trimming with our iCE TRIMMER HT-300 variable 3-way trimmer.
AUTOMATION AND WORKFLOW ZONE
We showcased our largest exhibition hall in the Horizon Innovation Park showroom, featuring both inline and standalone systems, as well as an AGV Logistics Zone and Workflow Zone. This zone was designed to provide visitors with a comprehensive understanding of the entire smart factory process. Printer vendors, workflow partners, and our own Technical Service Team were also present to represent their roles in this process.
AGV Logistics Zone
This area was dedicated specifically to our AGV Logistics and Pallet Transportation System. Using AGVs minimizes touchpoints, reduces manual labor, and eliminates the need for manual material transportation between production processes.
Workflow Zone
The seamless integration of our iCE LiNK Post Press Management system with other partners' workflow software is crucial to achieve end-to-end automation and visualization. The Workflow Zone was available for visitors to talk with Horizon staff and partners about what solutions are possible in each individual smart factory.
The biggest thank you to our workflow partners including: OneVision, SpencerMetrics, and Ultimate Tech.
SmartStacker ＆ Robotic Feed Smart Binding System
From printed B2 sheets to finished photobooks in a single pass!
Starting with our SmartStacker, printed B2 sheets enter the system and are made into book blocks! The book blocks are fed into the 4-clamp iCE BINDER BQ-500 perfect binder by a robotic arm and then perfect bound books are then transported inline to the iCE TRIMMER HT-300 variable 3-way trimmer for the final trimming.
Pressure Sealed Application System
*Collaboration with FUJIFILM BI
By combining FUJIFILM BI and Horizon technology, we can streamline the production of sealed applications, such as direct mail and other transactional mailing. Conventionally, these applications are made with offset presses, using adhesive varnishes, with offline gluing machines, or with adhesive impregnated paper, which can be a lot of extra work or money. But with FUJIFILM BI’s pressure adhesive toner and Horizon finishing solutions, they can now be done on-demand in short runs with digital printing
Applications are printed using FUJIFILM BI’s pressure adhesive toner technology and the Revoria Press PC1120S. From the printer, the sheets are sent directly through our SBM-100 universal sheet buffering module and then through our SmartSlitter for initial processing.
Applications cut down to size are then fed through our AF-408 small format buckle folder and pass through Hamamatsu’s Pressure Sealer, where the pressure adhesive toner is activated and the applications are sealed.
Inline Cut Sheet Press ＆ Sheet Processing System
*Collaboration with FUJIFILM BI
Cards and tickets with the touch of a button!
Applications are printed on the FUJIFILM BI Revoria Press SC285S and then accumulated in a buffering pile with the SBM-100 universal sheet buffering module. The sheets are then fed into our SmartSlitter and processed into cards and tickets.
Inline Cut Sheet Press ＆ Rotary Die Cutting System
*Collaboration with RICOH
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Our print-on-demand card making system provides users with finished stacks of card applications in one pass with no operator touchpoints.
Starting with RICOH’s Pro C9500 Press, applications are printed and then sent directly to the RD-N4055DM rotary die cutting system. Sheets are die cut into individual pieces and then separated from the waste and delivered to our GST-50RD gathering stacker, which delivers perfectly stacked piles of cards ready to be banded or boxed for shipping.
In this roll-to-book solution we featured the new plow fold technology of our BBS-56 continuous feed book block system integrated inline with a smart binding system.
The BBS-56 book block system takes a printed roll and turns it into glued book blocks with plow fold and starwheel technology. The HSF system configuration featured an ESF-1000 end sheet feeder and GF-500 gauze feeder for the ability to make both hard case book blocks and soft cover books.
iCE STITCHLINER Mark V
*Collaboration with TECNAU
For the first time ever, TECNAU web processing technology was integrated inline with Horizon’s iCE STITCHLINER Mark V for continuous feed booklet production.
The production flow begins with TECNAU’s unwinder, the u50, where the roll is unwound and then cut using TECNAU’s c51 cutter. The sheets are then transported with the t50s transporter and passed through the connection conveyor, IFU-50D. Finally, the sheets are stitched and trimmed with the iCE STITCHLINER Mark V at speeds of up to 6,000 booklets per hour.
iCE STITCHLINER Mark IV
*Collaboration with DAC Engineering
The iCE STICHLINER Mark IV is our latest sheet-fed saddle stitching system and at Horizon Smart Factory we integrated DAC Engineering's Gorika Vision sensor technology to help improve operator productivity and training. The Mark IV automates the processes of collating, plow folding, stitching, and 3-knife trimming to produce a wide range of booklet applications in one-pass at up to 6,000 cycles/hr.
Standalone Systems
In addition to inline systems we offered a variety of standalone equipment, including our iCE TRIMMER HT-300 three-side trimmer, iCE FOLDER AFV-566FKT cross folder, and our brand new iCE STITCHER SPF-2000 and iCE BINDER BQ-300.
iCE STITCHER SPF 2000
Our brand new booklet making system, iCE STITCHER SPF-2000, features ease-of-use, superior quality, and next level automation that can produce booklets at a rate of up to 4,700 cycles per hour. It also includes a new 15” control panel, higher productivity and landscape booklet capability.
iCE BINDER BQ-300
Our brand new single clamp perfect binder, iCE BINDER BQ-300, is a fully-automated and designed for ease-of-use, book quality, and production efficiency that can handle variable thickness production of up to 500 cycles per hour. It features a new 15” control panel, shortened job changeover time, new template feature, and improved automation.
NEW FOCUS ZONE
Not everything is digital, but everything can be automated! This zone is dedicated to show how Smart Factory Technology can automate offset printing workflows and featurd Horizon’s first ever flexible packaging machine.
Autopile and Jogging System
*Collaboration with RMGT
Starting with a pallet of wrapped paper, RMGT’s Autopile & Jogging System takes wrapped stacks and automatically unwraps the paper, re-stacks it, and then jogs the stack. The jogged stack is then automatically palletized for delivery to the press. For our event, we had the paper sent directly to our B1 Folder to be turned into signatures.
B1 Folder and Robotic Palletizing
*Collaboration with RMGT
A pile of B1 format sheets is delivered to the pile feeder of our B1 cross folder AFC-746F by RMGT’s NIPPER forklift AGV, which folds the sheets into signatures automatically. Signatures are then stacked with our PSX-56 press stacker and palletized by a robotic arm. The pallet is transported to the next production step by NIPPER.
MiniCABS ＆ Robotic Palletizing
*Collaboration with RMGT ＆ RISO
After receiving a pallet of signatures, an operator loads the signatures from the pallet into the MG-600 system gatherer, which gathers them into book blocks. These book blocks are then delivered inline to our four-clamp perfect binder BQ-500. Bound books then proceed to our three-knife trimmer HT-80 for the final trimming.
After cutting, the books go through third party machines for inline stacking and paper wrapping. The wrapped books are then picked up by a robot arm that helps print the content/job info of the package directly on the package’s outer surface with RISO’s Integlide Inkjet Printer. After this printing, packages are automatically palletized and carried off by NIPPER to shipping.
The robotic arm is integrated with Konica Minolta’s Forxai imaging AI technology that uses skeletal detection to ensure realtime workplace safety and automatically adjusts the speed of the arm when working alongside operators.
Pallet Wrapping System
The palletized books are taken from the MINICABS area to the automatic pallet wrapper and wrapped to prevent damage in transportation.
Flexible Package Processing ＆ Robotic Boxing System
Our Flexible Package Processing System is Horizon’s first step into the packaging industry.
Pouches are produced and printed on using third party equipment, then stacked, banded, and boxed automatically with our system. After stacking and banding, the pouches are rotated for even boxing and subsequently boxed automatically.
Printer Vendor Partners
We partnered with so many amazing printer vendors and partners to bring our smart factory vision to life! We owe a big thank you to: Canon Marketing Japan, FUJIFILM Business Innovation Corp., Hunkeler AG, KONICA MINOLTA JAPAN, INC., Ricoh Company, Ltd., RISO KAGAKU CORPORATION, RYOBI MHI Graphic Technology Ltd., SCREEN Graphic Solutions Co., Ltd, and TECNAU.
Other HSF Highlights
While our technology and inline systems stole the spotlight (rightfully so), we also offered a lot of other exciting events and activities!
We can’t talk about smart factory without showcasing our own! A few years ago, we completely transformed our operations in the factory to automate processes and reduce the time employees spent on repetitive tasks. Our fantastic factory tour team led the way, giving visitors a glimpse into the inner workings of our company and equipment.
Systems and equipment require maintenance and service in order to ensure customer success, and our Technical Support Team has been working hard to ensure dealers are supported with ample information, timely support, and top of the line service. At HSF 2024 they showed how iCE LiNK is used to help customers be more successful through data collection, monitoring, and analysis as well as new and future developments for technical service, support, and training.
As a Japanese company, sharing part of Japanese culture is both fun and important to us. We invited professionals to guide visitors through tea etiquette, preparation, and tasting, as well as the history and cultural significance of the tea ceremony. Both visitors and our staff enjoyed the experience and had a wonderful time!
We set sail on the Michigan cruise boat around Lake Biwa to celebrate Horizon Smart Factory 2024, our amazing team of distribution partners, and our customers.
THANK YOU!
Thank you so much to our customers and incredible team of distribution and collaboration partners, Horizon Smart Factory would not have been possible without you!
Now… let’s turn the Lights Out, see you next time!
