Logo Wide Format Automation Suite

Wide Format Automation Suite: Your solution for maximum press utilization and quicker turnarounds!

The Wide Format Automation Suite is OneVision’s software solution for wide and super-wide format printers. The combination of a workflow management system with an extensive prepress package and innovative technologies such as nesting or tiling & paneling automates the production processes of wide and super-wide format printers.

The flexible workflow management system enables wide format printers to define their production processes individually, standardize them and let them run completely automatically while making adaptions at any time.

The integrated prepress package checks incoming print jobs for possible errors, corrects and normalizes them and creates error-free print files (ISO-standard compliant) for a smooth, error-free printing.

Higher throughput and faster production times are easily achieved by automating time-consuming steps. The Wide Format Automation Suite allows wide format printers to achieve the perfect interplay between their printing presses and software. Improve your press utilization and benefit from significant saving potentials in terms of substrate, ink costs and processing time.

Asura Wide Format automates your production workflow

"Not only have we increased the number of jobs per day – we've also improved our profit margins. Using the Suite allows us to work significantly more flexibly, saving time and costs."

Michael Hiemann, Managing Director of Siepro KG

Logo Siepro KG

Videos: How to increase efficiency in your wide format printing

Watch our video and learn how your customers' files get all checked, preflighted, normalized and nested automatically with our Wide Format Automation Suite. See also a perfect interplay between between high-speed cutting machines and our Wide Format Automation Suite.

The Wide Format Automation Suite offers:

Fully automated quality control of print files at the prepress stage with subsequent optimization for errorless, print-ready files
An automated nesting technology that lets you virtually eradicate waste completely
A user-friendly page/ file editor to make last minute changes
A workflow management system that enables you to run your production workflow completely automatically, to keep your workflow flexible
Reach the maximum level of automation in your production, higher throughput and faster production times
Significant saving potentials in terms of substrate, ink costs and processing time

Replace time-consuming manual work by automated job tasks (automatic adjustment/ creation of bleed/ creating varnish and white masks)

Wide Format Automation Suite Access/Pro Variants: Overview features and functions

OneVision's Wide Format Automation Suite is offered in two variants: Access and Pro.

Function AccessPro
Workflow Management Solution: job tickets, metadata based workflows, drag and drop workflow editor  OneVision check mark - AsuraOneVision check mark - Asura
Prepress solution: preflight, color management, flattening transparencies, creation of printmarks, normalization  OneVision check mark - AsuraOneVision check mark - Asura
NestingOneVision check mark - AsuraOneVision check mark - Asura
Automatic merging of cut linesOneVision check mark - AsuraOneVision check mark - Asura
Individually selectable numbers of copiesOneVision check mark - AsuraOneVision check mark - Asura
Cut line manager: Accepts all cut line types and namesOneVision check mark - AsuraOneVision check mark - Asura
Auto correction of broken or incomplete cut linesOneVision check mark - AsuraOneVision check mark - Asura
Create varnish masks, white masks, missing bleedOneVision check mark - AsuraOneVision check mark - Asura
Onyx connectionOneVision check mark - AsuraOneVision check mark - Asura
Tiling and paneling            OneVision check mark - Asura
Extended prepress solution: barcodes, merge documents, cut spreads, output as images or EPS, overlay pagesOneVision check mark - Asura
Universal PDF editorOneVision check mark - Asura
InksaveOneVision check mark - Asura

How the Wide Format Automation Suite system works

  • Workflow Manager: Easy integration using either hot folders and/ or MIS using job ticketing. Straightforward UI where workflow processes can be created as you need them – simple drag and drop. Real time tracking of jobs.

  • Auto-Prepress: Identifying files that interfere with production – costing you money – is still a challenge. OneVision has all the relevant tools in place to identify any issues, to auto-repair typical errors, to color manage the files to the output profile you need, to reliably flatten transparencies and also to normalize files.

  • Cut Line Manager: Incoming jobs may use different names for their cut lines and also some of them might be broken or incomplete. This suite will fix these issues automatically. All names for cut lines are accepted.

  • Tiling and Paneling: File formats that are larger than the maximum print format can be automatically tiled/ paneled and split into multiple formats for production.

  • Nesting: The complete automated solution reduces waste to an absolute minimum. OneVision‘s technology will automatically position complex shapes whilst maximizing material usage and creates a separate PDF with only the cut lines that can be used by the cutter.

  • Onyx Connection: Downstream printing presses can be addressed directly with the optimized print files.
Auto ganging output
Auto ganging output created with the freeform nesting module
Extracted form for the cutter
Extracted form for the cutter

Technical highlights at your prepress stage

Nesting: Eradicates waste almost completely

Examples nesting
Auto ganging output created with the freeform nesting module
Examples nesting
Extracted form for the cutter

With Nesting:

Complex shapes are positioned automatically whilst maximizing material usage
Creation of a separate PDF with only the cut lines that can be used by the cutter
The extremely fast technology reduces waste to an absolute minimum

Cut Line Manager: Accepts all cut line types and names

Example cut line manager

With the Cut Line Manager:

All cut line names and types are accepted
Broken or incomplete cut lines are fixed automatically

Example tiling & paneling functionality

With Tiling & Paneling:

File formats that are larger than the maximum print format can be automatically tiled/ paneled and split into multiple formats for production

Flatten Transparencies: Removes transparency from a PDF-file

Image flatten transparencies

With Flatten Transparencies:

Recalculation and restructuring of elements
Original appearance of image remains
Ideal file optimization for printing

Benefits with flatten transparencies
Shorter RIP times due to
• Less complex files
• Less data volume as invisible elements are removed
Errorless printing
No occurrence of color issues during the RIP

Preflight: Detailed analysis on file quality

Asura module Preflight

With Preflight:

Preflight report: All file errors are visualized as an extra file
More than 130 different errors can be discovered automatically
File issues are identified right away -> for immediate repairing
Preflight results are used for workflow control

Place Watermarks: Places a watermark on the files

Image Asura module place watermarks
Image Asura module place watermarks

With Place Watermarks:

Watermarks ensure a secure preview of images and documents as well as the possibility to mark documents e.g. as "confidential"
Marks file for customer approval
Prevents misuse of customer data and images


4D-Color-Management: For significant print quality improvements

Asura module 4D Color Management

With 4D-Color-Management:

Preserves CMYK black
Higher printing quality – less customer complaints

Case Study: How our customers successfully automate their wide format printing processes

Case Study Siepro KG

“Not only have we increased the number of jobs per day – we’ve also improved our profit margins.”

Automation in the world of wide format printing: thanks to the implementation of the Wide Format Automation Suite, Siepro KG was not only able to achieve a significant increase in the number of print jobs per day – the company also saved materials costs and improved its profit margins.

Growth rates in wide format printing are impressive. Web-to-print solutions and increasing demand for wide format printing for media and advertising applications mean that the number of print jobs required is constantly increasing. To ensure that these jobs are delivered on time, full automation is now more in demand than ever before. However, how can production processes be optimized as effectively as possible in order to achieve higher revenue and improved print quality? Answers to these and other questions are provided by the success story behind Siepro KG, a wide format print specialist. The company, which is based in Swabia in southwestern Germany, is an established foil printing specialist and supports the printing needs of global players such as Siemens, Meto, Bosch, Fein, Weleda and many more. In the following interview, Michael Hiemann, Chief Executive of Siepro KG, explains how significant savings can be achieved in relation to material costs while also increasing production efficiency in respect of inbound jobs, pre-print file data preparation, and nesting across multiple print jobs.


As a wide format print shop, which products and services do you offer? How high is your average order volume per month?

We specialize in foil printing with an extremely wide range of materials, such as advertising and product stickers, sticker sheets, magnetic foil, backlit foil, wobblers and crowners for use in POS, signage, displays, adhesive and static foil sheets, floor stickers, and 3D money stickers. Our order volume is approximately 4,000 jobs per month.

What kind of machines and print processes do you use in your company?

To produce our thirty different products, we currently work with over twenty large format systems. This involves the use of a wide variety of machinery, such as the OCÉ Colorado and OCÉ Arizona as well as machines from Epson, Seiko, Oki and Zünd. For our print processes, we use UV Offset, screen printing and digital printing.

How has the market for wide format printing changed over the last few years, particularly in respect of digital transformation (e.g., when you consider how online printing has been incorporated)? Which challenges arise for wide format print shops as a result? What were the greatest problems that your business faced?

Online printing has meant that profit margins and production times have suffered a drastic downward correction, while customers’ quality expectations are as high as ever. To combat these issues, processes must be designed to be as efficient and cost-effective as possible. Increasing our throughput with no increase in staff costs meant that individual steps in the workflow and entire production processes needed to be automated.

Why did you decide to acquire the OneVision Wide Format Automation Suite? What were your expectations of the software? To what extent has the software suite changed your production processes?  How did you work beforehand?

We had previously worked with impositioning software from Canon/Zünd. This required some manual input, but with the constant increase in orders, it eventually stopped being economically viable. After a long search, and having evaluated some other systems, OneVision’s Wide Format Automation Suite was able to offer exactly what mattered most to us: a comprehensive software solution with workflow management, a pre-press package and innovative technologies such as nesting and an integrated cutline manager, all incorporated into a single system. All these features from OneVision were nearly tailor made to suit our requirements.

To what extent does the OneVision solution meet your expectations?

So far, I think we have only made use of a fraction of the possibilities that the solution offers us and we are already extremely happy. Using the suite allows us to work significantly more flexibly, saving time and cost. The close collaboration with OneVision allows us to give constant, direct feedback. As such, work is already underway on additional solutions, such as barcode integration for Zünd, so that we can tailor all our options to fit our expectations precisely.

Was it difficult to integrate the OneVision solution into your existing processes and systems landscape?

No, the solution was implemented in parallel with our existing operations and was implemented virtually flawlessly.

To what extent was the pre-press process in wide format printing (such as preflighting/standardization, etc.) already automated? Which changes and benefits came about as a result of implementing the Suite?

As a rule, about 90% of the data we received was properly prepared. The remaining 10% had to be “manually” corrected and optimized for printing. Thanks to the Wide Format Automation Suite this is now handled fully automatically resulting in a smooth, nearly flawless production flow.

What benefits does the OneVision nesting technology offer in comparison to your previous process?

The OneVision nesting technology means that complex shapes can now be placed so that not only do we require less manpower, waste is also reduced significantly. Automatic cutline merging means that we can achieve cutting times that we estimate as 70% faster.

Substrates used in wide format printing are highly variable (such as glass, wood, textile fabrics, foil, etc.) and often highly cost-intensive. What effect has the deployment of the Wide Format Automation Suite on your consumption of substrates?

Quite clearly, there has been a significant reduction in the use of substrates and this has also increased our profit margins.

How highly would you rate the degree of automation in the Software Suite?

I don’t think you could ask for more!

What effect has the Software Suite had on your machine utilization and your throughput times?

Our machine utilization actually decreased as a result of the nesting, creating more space for new jobs. Whereas we previously needed to print ten meters for a job, it might be more like nine meters now.

How satisfied are you with the support offered by OneVision? What would you and your co-workers say, if you and they were asked about your experience with OneVision and the products?

We only have positive things to say. The support works really well and we already have a good working relationship. It really addresses each product individually and specifically and is implemented accordingly.

Download the complete article HERE

         

Image: Siepro KG's high-speed printing machine "Colorado" from hardware manufacturer Océ works perfectly with the Wide Format Automation Suite

 

Production process with OneVision's Wide Format Automation Suite:

Production process with OneVision Middleware