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
Integration, MIS, Web shop, Nesting, Tiling/Paneling, Barcodes, varnish masks, white masks

"Not only have we increased the number of jobs per day – we've also improved our profit margins. Using the Wide Format Automation 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 automatic quality control of print data during prepress and subsequent optimization of print data including preflight, converting of complex pages into images, flattening transparencies, file normalization, etc. for error-free, print-ready files and trouble-free printing
  • 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 perfect bleed/ creating varnish and white masks)

Wide Format Automation Suite: Overview features and functions

OneVision's Wide Format Automation Suite offers the following features:

Function IncludedOptional
Workflow Management Solution: job tickets, metadata based workflows, drag and drop workflow editor  OneVision check mark - Asura
Prepress solution: preflight, color management, flattening transparencies, creation of printmarks, normalization  OneVision check mark - Asura
NestingOneVision check mark - Asura
Automatic merging of cut linesOneVision check mark - Asura
Individually selectable numbers of copiesOneVision check mark - Asura
Cut line manager: Accepts all cut line types and namesOneVision check mark - Asura
Auto correction of broken or incomplete cut linesOneVision check mark - Asura
Create varnish masks, white masks, missing bleedOneVision check mark - Asura
Tiling and paneling    OneVision check mark - Asura
Connection to Zünd Cut CentreOneVision check mark - Asura
Connection to DFE/RIP (e.g. Onyx, Caldera, EFI Fiery)           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. Assembly lines can be structured into individual phases in order to maintain a clear overview of the workflow.

  • 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. Areas in the subject that are not to be cut (e.g. faces) can simply be slid or removed using the PDF editor.

        File formats that are larger than the maximum print format can be automatically tiled/ paneled

  • 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 with the wide format automation suite
Auto ganging output created with the freeform nesting module
Examples nesting with wide format automation suite
Extracted form from the wide format automation suite
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
  • Supports double sided nesting

 

Find out more in our blogpost: "Wonder Weapon Nesting and Step & Repeat" »

Cut Line Manager: Accepts all cut line types and names

Example cut line manager with wide format automation suite

With the Cut Line Manager:

  • All cut line names and types are accepted
  • Broken or incomplete cut lines are fixed automatically
  • The print sheets thus always have uniform, standardized cutting lines

Tiling and Paneling

Example tiling & paneling functionality of wide format automation suite

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

Add Hemstitch to print file

Adds hemstitches to supplied print data

The print image can be flipped on all sides or white space can be added

For double-sided printing, the motif can be chosen between front and back

Perfect Bleed Generation

Wide Format Automation Suite - Generate Bleed

The software checks the print file along the trim box or any other trim line. The necessary trim is intelligently generated automatically by pixel mirroring or pixel stretching.

missing bleed is added automatically
no manual intervention in the print file
print files do not have to be requested again
no interference, cutting tolerances in finishing are insignificant

How does Generate Bleed works exactly? »

Add Custom Marks/Objects

Add Custom Marks to page with wide format automation suite

With Custom Marks :

individual objects/marks – such as eyelets – can be placed on the page

own standards can thus be maintained in the usual way

future objects/marks for new machines or operations to be connected can be inserted without any problems

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

Success stories: How our customers successfully automate their wide format printing processes

OXY: Seamless production workflow, more efficiency

Why wide format printing specialist OXY counts on automation software for its broad application range.

Oxy – an expert in marking and signage solutions (production of banners, displays, wrappings for means of transportation, flags, floor graphics, industrial labels…)  that has been supporting its customers for over 40 years – has chosen OneVision Software as its trusted partner for automating their print production workflows.

OXY Logo using Wide Format Automation Suite      OXY production workflow with Wide Format Automation Suite

 

Mr. Leleu, you are a design engineer specialized in automation, production workflows and IT, you have been working for Oxy for three and a half years. What makes Oxy a first class company?

Oxy's strong point, due to our size, is our ability to respond to all types of requests, whether it is for wall screen printing, sublimation or large format digital printing. We are able to satisfy both very demanding customers on museography with an outstanding printing quality and industrial customers such as Airbus or SNCF, who ask us to respect specific technical plans and precise conditions in terms of manufacturing. Oxy can manufacture a totem, a technical label or make a covering for a train or an airplane.  

 

In 2019 you have decided to invest in workflow automation software. What was the reason to do that?

When we purchased Wide Format Automation Suite in late 2019 we had a multi-phase project:

The first phase was to automate our sales administration work. For example, it took us a lot of manual work and time to create delivery notes and invoices. Thanks to the easy integration of our ERP system with the workflow management system Workspace Pro X this task is now fully automated. Technically, this was achieved through making use of properties and barcodes in a VDP (variable data printing) setting.

When in 2020 we were affected by the COVID-19 pandemic and wanted to offer new products online, such as plexiglas panels, anti-projection caps or signage solutions, the OneVision software allowed us to link the web to print sales website to our ERP. Without the OneVision software we would not have been able to feed the orders into our ERP and would not have been able to track the flow of orders that came in.

Now, working with the same software, we are preparing for automation in the production of files, especially for large formats. This is going very well, and we have already managed to save a considerable amount of time on the production of one of our large accounts.

 

How did you become aware of OneVision and why did you decide to automate with the Wide Format Automation Suite?

We attended the presentation held at C!Print 2019 in Lyon. We particularly appreciated the fact that OneVision Software can make direct links with different types of machines, including Canon, Zünd and Caldera for our part. We drew up the specifications, taking into account criteria such as price, flexibility of the solution, ease of integration with our ERP system, XML file processing (allowing for the link with our web to print solution), and we chose OneVision. We are very happy with this choice.

 

 OXY – OneVision Wide Format Automation Suite

 

How does your automation workflow look like today?

Today, we feed our orders directly into our ERP. The work of the designers is concentrated on activities with real added value and the proofs are also for a large part automatically produced. We are about to launch the software on the automation part of the production: preflight with barcode management and camera points. To date, the software with its multiple possibilities satisfies us from A to Z.

 

How did the installation of the Wide Format Automation Suite go? Since working with the software, how would you rate OneVision's support?  

The installation of the Wide Format Automation Suite went smoothly. The ramp-up phase lasted 3-4 days, we were trained and since then, whenever we need help, we contact the OneVision support team. We have a very good relationship with them and what is important is that OneVision's consultants do not keep information to themselves. The goal is for the customer to become autonomous. I really appreciate that.

 

How many people are involved in managing the Automation software? 

I am the only one in charge of this software, but depending on the way of using it, it might be interesting to have a partner.

 

Could you summarize your experience with OneVision in one or two sentences? 

OneVision has allowed us to automate repetitive, low value-added tasks by adapting to our ERP environment. The support team is very responsive and allows us to move forward on various issues. OneVision listens to the customer, especially when it comes to updates that take into account customer suggestions.

 

Pick up the whole case study in one download now!

posterXXL

posterXXL: The software is the key

In its current issue, the German trade magazine "Print & Produktion" reports on how the Munich-based specialist for photo services masters the daily fluctuating ordering patterns of its customers. The perfect mix of automation and manual intervention has helped posterXXL to a production workflow on time, high flexibility and more profitability.

The large format printing machine Arizona for plate printing is automatically supplied with optimized print data by the Wide Format Automation Suite.The digitalization in photography and new possibilities by the smartphone have opened up new markets for the printing industry. Only few customers still capture their most beautiful moments in photo albums. The vast majority uses photo books, decorate their smartphone cases with a picture of their family or put up printed canvas with holiday photos in their living rooms. Since 2004 posterXXL, one of Germany's leading providers of photo services in digital printing, produces exactly such photo products. In order to further strengthen and expand its market position, it is particularly important for posterXXL "to deliver on the promise we make to the customer, usually within a few days," explains Bastian Götz, Department Manager Plates at posterXXL.

 

 

Product variety and high production costsThe Wide Format Automation Suite helped posterXXL to an automated production on time.
On a daily base the Bavarian printing company is confronted with a very variable order income. “We don't really know when the customers are ordering, how they are ordering, what marketing campaigns they are responding to or not”, describes Susanne Feller, Head of Production at posterXXL, one of the daily challenges. In addition, there are "many different products, all of them requiring different production times, because for one product there are several different production steps involved whereas for another there might only be three, for example" adds Feller. “Managing the production flow that way that we can guarantee everything is on time, that is the challenge” says Max Baum, Vice President Engineering at posterXXL.

Moreover, for many big print service providers, running production sites in Germany is becoming increasingly unprofitable; high costs for staff, buildings and infrastructure. “Nobody can imagine that a print service provider with quite some manual work can actually work pretty economically in Munich” says Susanne Feller. So how can these aspects – profitability, product diversity and fluctuating order income – be managed while meeting the delivery time?

posterXXL masters this balancing act with a perfectly matched mix of full automation of their production processes and manual intervention. “To save time, of course, we want to automate as much as possible” explains Max Baum. Nevertheless, it is necessary to react flexibly and quickly to changes in production, for example in the case of a machine failure. However, these manual interventions should  not have any effect on the production process, disrupt it or even lead to a loss of time.

Bastian Götz, Susanne Feller and Max Baum describe the daily challenges of production.Automation with manual intervention
Production at posterXXL starts off in a classic way: In the web shop, the customer selects the product ranging from posters and canvases, over photo books and direct prints to printed bags and individual puzzles, and checks out. The next steps are fully automated. The digital printer therefore uses the Wide Format Automation Suite from OneVision. The images of the customers are uploaded via an interface from the web shop to the software suite, that processes the data according to fixed schedules. “An assembly line that processes the files automatically can consist of up to 28 steps in order to get a printable PDF for our machines” explains Bastian Götz. The choice of the production line depends on the substrate to be printed on. posterXXL prints on both, on plates and on rolls. Hence, in addition to rigid foam/PVC sheets or alu-dibond sheets, various foils or photo and picture printing papers are also used. The print service provider also produces various photo gifts using the sublimation printing process. The individual production lines prepare the images for printing and further processing, move them to suitable folders, rename and sort the files, set them up and then create a normalized nesting. This can be set specifically and adjusted for an optimal material utilization: “When is the software allowed to write a nesting, when should it perhaps wait for other pictures, for other orders so that we have as little waste as possible” describes Bastian Götz the nesting with Wide Format Automation Suite.

Via a direct connection to the DFE, the Wide Format Automation Suite sends the nested print file to the printing presses, such as “large format roll-to-roll printers, classic DesignJets from HP and Arizona from Canon” names Susanne Feller only a part of the machinery. In addition, posterXXL uses printing machines from Mimaki (JV300) or HP (Latex). For post-press, the Wide Format Automation Suite "generates files explicitly suited for the post-press systems (for example ProCut by Zünd/Océ)," says Bastian Götz. “This means that subsequent systems are prevented from queues or crashes caused by heavy print file volumes. Therefore we can guarantee a faster workflow. In this final process step the images are cut, “the canvas is mounted, the book is bound and in the end the product is packed up and shipped to the customer as quickly as possible” Feller completes the process.The Wide Format Automation Suite also provides post-press systems with production data tailored to their needs.

Flexible automation, profitable production
In addition to the better material utilization, posterXXL benefits from two major advantages due to
the automation: Thanks to the flexibility of the Wide Format Automation Suite the level of automation can be adjusted and changed at any time. Depending on the requirements, check points can be implemented in the workflow and enable manual intervention. This allows the photo printer to adapt its workflow to production conditions without disrupting production. Bastian Götz is sure that this flexibility comes from the user-friendly usability of the software: “You don't need an IT education, you don't need developer knowledge to operate the system. And if you really don't get anywhere, OneVision also has a super Helpdesk you can contact by phone or e-mail.”

The independence from IT also counts as one of the big advantages to Susanne Feller. ”What we appreciate the most is that we can work on the software ourselves.” Changes to the products or the production can be implemented and modified quickly and flexibly, without the IT department accessing it. Hence, posterXXL masters the delivery promise significantly better. The different products “all have different production times, hence, managing and timing the different production times and everything that way that it gets out the door at the same time and in time, that's the crux. And that's exactly what we're doing much better now with OneVision” the production manager sums up.

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 case study of Siepro KG 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 Wide Format Automation Suite

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