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Automated “On Command” plate management and handling systems...

the printer’s gateway to fully integrated print manufacturing.

Burgess Industries

Engineering, Automation, Design & Commitment

To our Valued Customers:

Behind our success is a long-standing commitment to engineering excellence. Our Company was founded upon the principle that we would only design and manufacture products that were Best In Class; technically superior to anything else currently available in the market, and has been do-ing this for nearly 30 years. We continue that tradition by ensuring that our customers attain sys-tems that are demonstrably state-of-the-art in concept, construction, and reliability. In product engineering, manufacturing, and service, every Burgess product must meet the most demanding requirements of the industry. And Burgess engineers regularly assess the performance standards and technology accepted by the industry, and ask, “Can Burgess do this better?”

Burgess remains the industry leader by providing innovative, high value, automated solutions using standard components in non-standard confi gurations. This custom confi guration approach combining modular equipment with expert Design Planning and Project Management provides maximum fl exibility, proven reliability, and lowest cost to meet each customer’s unique require-ments.

Consulting on every phase of your project is an everyday undertaking at Burgess. Behind our products stands a team of sales representatives, highly trained and experienced installation specialists, and our headquarters staff to meet your every need. And we don’t forget about you after the sale: we are ready to support your needs whatever they may be.

At Burgess, we do not want merely satisfi ed customers. We want customers who are delighted with our results, and proud to be a showcase for the success of our partnership with them in creating the ideal solution for their unique needs and situation.

Sincerely and Be Blessed!

DJ Burgess and The Burgess Team

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Privately Owned

Burgess Industries Inc. has been a privately-held “World Class” corporation, known for design and manufacturing of quality equipment and automation since 1978. We base our business approach on some very basic principles: innovation, craftsmanship, integrity, and service. The company’s “indepen-dent” culture and fl exible structure is designed to empower its people to react quickly to changing market conditions in a much shorter cycle than larger corporate entities. This leads to early recognition of shifts in industry trends and positions us to design products that meet our customers chang-ing needs more proactively, with focus on providing high-value, cost-justfi ed solutions. We have built a solid reputation on being more fl exible and more responsive to our customers’ specifi c application challenges and needs as the industry changes.

Company Introduction

The Minneapolis location of our corporate offi ces and state-of-the-art manufacturing facilities allows quick and easy access to all major cities and shipping ports for world-wide on-time delivery, service, and support. The company continues to make signifi cant investments in the retooling of our digital software and hardware computer, business, and manufacturing equipment to provide our employees and customers with the very best in sophisticated communication, reporting, planning, forecasting management, precision parts, design tools services and products.

Burgess has established relationships with a partnering network of over 200 suppliers, providing expertise, high-precision fabricated-machined parts, electronic components and access to all new and evolving technology.

Partnerships Prevail

These partnering relationships are the driving forces behind Burgess’ com-petitive edge in leading design, quality, pricing, delivery and service. Bur-gess’ manufacturing strength provides great fl exibility in controlling and meeting the production demand needs of our customers. We’ve perfected the process of moving design concept, to prototype and pre-production to production, in a very short period of time, allowing our customers to take full advantage of market opportunity and potential.

Significant Burgess Industries Milestones

1978 Founded on Microfi lm Imaging Technologies1980 Patented Thermal and Ammonia Processors 1982 Largest OEM Contract for Exposure Device for Microfi lm1985 Acquisition of Berkey/Pako U.V. Imaging/AddaLUX 1991 Acquisition of Carlson Company Plate Bending/Register 1993 Heidelberg Gapless Press Robotics/Auto-Plate Bend 1996 ‘Print Control” CTF After-Image Register 1997 Super Bender CTP Plate Bending 1999 India Manufacturing Alliance1999 CTP In-line Automation First Major Installation at Le Journal de Montreal2003 Awarded Largest Single Order Plate Management Handling System in the World2004 Detroit News - Largest CTP In-line Newspaper World-Wide2005 Creation of Burgess Technologies, Inc. (BTI)2006 Largest CTP In-line Commercial Print Site in the World

»»»»»»»»»»»»»»

Burgess Corporate Offices

About Burgess Industries

Burgess Industries’ Manufacturing, Sales, Engineering, and

Technical Support offices in Minneapolis, Minnesota, USA.

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What is The Gateway?

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The Gateway is your ability to partner with Burgess Industries to create

a fully-integrated manufacturing system that will manage the continu-

ous process flow of delivering “press-ready” in-register plates for each

cylinder on press.

Modular in design, Burgess’ Automation Technology can be “Custom-Con-

figured” to your exact building, press type, and application requirements.

Dream, Design, Create, and Implement the Future with Burgess Industries.

The Gateway To Fully-Integrated Manufacturing!

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Plate

TransportReporting

Plate

Forming

Sort,

Stack, &

Deliver

System

Management

The Printer’s Gateway to Fully

Integrated Print Manufacturing.

We provide products and automation for all CTP imaging devices and applications.

Burgess Industries

provides a complete “Print Control”

system of specialists, products, and techni-

cal services that allow you to partner with a

single source manufacturer that guarantees

precise register control, plate handling and

transport, from image assembly through plate

on press.

CtP Press

• Shift Reports• Database• Statistical analysis• Preventive Maintenance• Historical reports• Uptime reports• Custom

• Single and Dual Level Sort-Stacking Stations• Stacking Carts • Indexing Units• Mobile Indexing Cart

• Punching• Bending• Shearing• Corner Notching/Cutting

• Entry Systems• Rotators• Bridge Systems• Elevators• Dual Plate Highway• Thru-the-Wall Transport• Dummy Plate Loaders• Auto Plate Feeders

• BPM Supervisory System• Plate Traffi c Control• ORV - Optical Registration Verifi cation • “Image Patch” Plate Inspector• “On Command” Bar-Code Scanning• Remote Diagnostics • BII Service Eye

We provide products and automa-tion for all press manufacturers presses and applications.

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Identifying ways to work more efficiently has long been a tradition

at Burgess Industries.

In 1993, Burgess Industries embarked upon a major engineering design

program that would embrace the future need of integrating new

high-speed press and emerging CTP technologies for our customers.

Automation would be the single driving factor for impacting our

customers profitabilty. By design this technology allows for the

convergence of newsprint and commercial printing. Thirteen years

later we are the leader in in-line plate management and handling systems.

The Convergence of Newspaper & Commercial Printing

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Auto Plate Feed

As plate volume or size increases, the more susceptible plates are to damage and mis-register caused by poor handling, manual positioning and alignment. Burgess’ auto plate feed system automatically feeds the plate into the punch/bender, registers it then returns the plate back to the operator or passes it through to the next module in an in-line system. For very high volume situations the dual auto feed will handle up to 250 plates per hour per punch/bender.

Programmable Bending Cams/Alloy Selection

Burgess Programmable Bending Cams can be pre-programmed to accommo-date the “spring back” characteristics due to different aluminum alloys used in plate manufacturing by various manufacturers. This provides for a much tighter, more accurate fi t of the plate to the press cylinder eliminating plate slippage and cracking. This enhances plate-on-press performance and longev-ity. Pre-programmed bend characteristics can be implemented automatically via bar-coded information on the plate or via operator selection on the sys-tems “Touch Screen” instrument panel.

Burgess Internal/In-line Press Notching

Burgess’ Internal In-Line Press Notching Systems can eliminate up to 5 off-line steps in the plate-making process. For customers with CTP plate-making sys-tems our automatic in-line press notching eliminates the need to post punch the CTP plates. After the plate is registered by one of the automatic register systems in the punch/bender, the in-line press punches move into position and notch the plate. The punch heads are mounted on high precision dual bi-directional linear slide systems which allow us to notch for different press confi gurations with the same cutting assembly and it simplifi es the process of

accommodating future Web Width Reductions at a nomi-nal cost compared to our competitors.

Burgess “On Command” SuperBender

With our “On Command” programmable SuperBender technology you can punch and bend for many different presses on the same punch/bender. Optional features can be incorporated with the Burgess’ plate handling and management system for high volume applications.

Multiple Register Systems

Burgess offers multiple Register Systems including Electronic Tri-Point Robotic Pin, “B-Opts” Optical/Tri-Point Robotic Dual Register, and/or Holes Over Pins for CTP and conventional plate making applications. The functions of the automated punch/bender and the register sys-tems utilize precise robotics to position the plate into register, elimi-nating operator involvement. Highly advanced optical, electronic, and magnetic sensors are utilized throughout the system to ensure in-line and off-line precision plate loading and plate bending performance. The sensors allow the Programmable Logic Controller (PLC) to com-municate with the plate management system modules and manage the plate punching, bending and transport processes.

Programmable Moving Anvil for Optimal Control of

Lead and Tail Edge Bends

Burgess’ Programmable Anvil System provides fl exibility and control producing bend angles and lengths for precise plate-to-cylinder fi t tol-erances. Our patented “Split Bearing” cam/anvil bending assemblies form each bend independently of each other assuring precise plate on press cylinder register and fi t. Our non-contact bending principle assures maximum plate strength and guarantees bend dimensions to .001”.

Programmable Logic Controller (PLC)

The PLC is the operating brain of the system and is used for controlling all areas of automation, including the “Communication Linking” for in-line systems, Self Diagnostics with LED readouts for easy and accurate trouble shooting and Ethernet Connectivity (optional) for world-wide remote factory assistance.

System Robotics

Many competitive automated systems use “pushers” to position the plate into register position leading to inconsistencies due to vari-ances in plate size from batch to batch. Burgess precision robotic grippers pull the plate into po-sition guaranteeing precise register every time. Burgess’ register systems completely eliminate any dependency on the operator for accurate positioning of the plate and ensure high levels of repeatable performance.

In-line or Off-line, Burgess Punch/Benders are the Finest in the World

Direct, Rotate, & Transport Plates

From any CTP Device to any Press Cylinder Type

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Lift-Up Entry Conveyors

Lift-Up Entry Conveyors receive the imaged plate from the CTP Plate Pro-cessor or post-bake oven. They can be adjusted to any height and “Lift-Up” out of the way for operators to easily pass through and around the CTP Processor or Plate Management System (an industry exclusive feature).

Multi-Directional Plate Transfers

These very versatile modules can receive plates from the CTP plate pro-cessor, post-bake oven or other plate management modules, then direct them either straight ahead or to the right or left within the plate manage-ment system. Overhead rotator modules can also be mounted to combine functionality using the same fl oor space. They are also used for depositing plates into standard single or dual-level sort-stack bins.

Plate Rotators

Plate Rotator modules control plate orientation for proper transport and entry into the in-line punch/bender, sort-stacker, or elevator modules. They can pick up the plates and physically rotate them from overhead or from below. Generally, rotation is 90 or 180 degrees.

Belt Transports

Belt Transport modules utilize only belts to transport from one point to another and are designed to simply move the plates straight ahead from point A to point B. They can be as long as required and are typically used as a spacer in a long run across a room, or as a crossover connectivity module between punch/bend lines.

“Traffic Control” Transport Bridge Modules

These are designed to integrate multiple lines of CTP automation for re-dundant operation and/or provide a pathway to other punch/bend lines or areas for continuous operational throughput. These are generally made up of lift-up crossover conveyors and belt transports.

Integrated Plate Transport & Delivery

Dummy Plate Loaders/

Unloaders With Plate

Transport

These eliminate operator in-volvement in creating “press ready” dummy or “blank” plates for press production. The module automatically loads fl at dummy plates “On-Command”, into the CTP automation line for punch / bend / sort / stack of “press ready” dummy plates. This module is often staged in the plate management system between the CTP plate processor and in-line punch/bender and acts as a plate pre-positioning module for fi nal entry into the punch/bender. It has an emergency reverse load function that when activated by an unavailable in-line punch/bender, will automatically pick up plates coming out of the CTP plate processor and unload them off the in-line punch/bend system onto the dummy plate loader mobile cart where they can be wheeled to another punch/bend line for completion of the process. This redundancy allows the CTP device on the unavailable punch/bend line to continue operating at full speed.

Dual-Level Plate Highway/Through-the-Wall Transport/Dual-

Level Sort-Stack Stations

Where fl oor space is at a premium and the plate production volume is very high, Burgess provides the dual-level plate highway, through-the-wall trans-port, and dual-level sort-stack station modules in the prep or press room. These options create effi cient, productive workfl ows with a minimum foot-print. They are manufactured with the same proven components as our stan-dard modules (noted above) but are stacked two high to handle twice the plate production volume in the same footprint. They are fed by vertical multi-level plate transport indexing high speed elevator modules for smooth effi cient operation. However limited your space, we will design the best solu-tion for your application, regardless of plate production volume.

Burgess’ automation transport and delivery modules are designed to transport and deliver the “press-ready” plate to its designated stacking location. System modules provide plate traffi c control, plate protection, and tracking of the plate throughout the entire transport and delivery function. The mod-ules can transport plates forward or backward, right or left, pause and hold, rotate from below or above, index, sort, stack, crossover, elevate or eject. Our modules create holding stations when other stations down-line are busy, and plate transport from pre-press to anywhere in prep or the pressroom. Our products utilize precision optical sensors for “go/no go” operation, non-stick protective belts (standard or heat resistant) and rubber-coated wheels for optimal control and protection of imaged “press-ready” plates. Each transport module has adjustable speed control, precision motor drives for many years of 24/7 operation, and can be custom-confi gured for any plant application.

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The Burgess Punch/Bender is designed to perform to exacting

tolerances not able to be seen by the naked eye. Specific hardened

steel, precision machining, state-of-the-art electronics and

pneumatic components provide years of 24/7 predictable, reliable,

repeatable production performance for multiple press applications.

The Core Component of

Plate-On-Press Performance

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The continuity of register becomes the relationship between

the image and formed plate bends and plate register notches.

The lead and tail bends must be straight and parallel with each

other for maximum plate on press register and performance.

How Plates and Cylinders Become One

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The World's Finest Punch/Benders

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Auto Plate Feed

As plate volume or size increases, plates are more susceptible to damage and mis-register caused by poor handling, manual positioning and alignment. Burgess’ auto plate feed system automatically feeds the plate into the punch/bender, registers it, then returns the plate back to the operator, or passes it through to the next module in an in-line system. For very high volume situations, the dual auto feed will handle up to 250 plates per hour per punch/bender.

Programmable Bending Cams/Alloy Selection

Burgess Programmable Bending Cams can be pre-programmed to accom-modate the “spring back” characteristics due to different aluminum alloys used in plate manufacturing by various manufacturers. This provides for a much tighter, more accurate fi t of the plate, to the press cylinder, eliminating plate slippage and cracking. This enhances plate-on-press performance and longevity. Pre-programmed bend characteristics can be implemented automatically via bar-coded information on the plate or via operator selection on the systems “Touch Screen” instrument panel.

Burgess Internal/In-line Press Notching

Burgess’ Internal In-Line Press Notching Systems can eliminate up to 5 off-line steps in the plate-making process. For customers with CTP plate-making sys-tems, our automatic in-line press notching eliminates the need to post-punch the CTP plates. After the plate is registered by one of the automatic register systems in the punch/bender, the in-line press punches move into position and notch the plate. The punch heads are mounted on high-precision, dual bi-directional linear slide systems, which allow us to notch for different press confi gurations with the same cutting assembly, and it simplifi es the process of accommodating future Web Width Reductions at a nominal cost compared to our competitors.

Burgess “On Command” SuperBender

With our “On Command” programmable SuperBender technology, you can punch and bend for many different presses on the same punch/bender. Optional features can be incorporated with the Burgess’ plate handling and management system for high volume applications.

Multiple Register Systems

Burgess offers multiple Register Systems including Electronic Tri-Point Robotic Pin, “B-Opts” Optical/Tri-Point Robotic Dual-Register, and/or Holes Over Pins for CTP and conventional plate-making applications. The functions of the automated punch/bender and the register sys-tems utilize precise robotics to position the plate into register, elimi-nating operator involvement. Highly advanced optical, electronic, and magnetic sensors are utilized throughout the system to ensure in-line and off-line precision plate loading and plate bending performance. The sensors allow the Programmable Logic Controller (PLC) to com-municate with the plate management system modules and manage the plate punching, bending and transport processes.

Programmable Moving Anvil for Optimal Control of

Lead and Tail Edge Bends

Burgess’ Programmable Anvil System provides fl exibility and control producing bend angles and lengths for precise plate-to-cylinder fi t tol-erances. Our patented “Split Bearing” cam/anvil bending assemblies form each bend independently of each other assuring precise plate on press cylinder register and fi t. Our non-contact bending principle assures maximum plate strength and guarantees bend dimensions to .001”.

Programmable Logic Controller (PLC)

The PLC is the operating brain of the system and is used for controlling all areas of automation, including the “Communication Linking” for in-line systems, Self Diagnostics with LED readouts for easy and accurate trouble-shooting, and Ethernet Connectivity (optional) for world-wide remote factory assistance.

System Robotics

Many competitive automated systems use “pushers” to position the plate into registerposition, leading to inconsistencies due to variances in plate size from batch to batch. Burgess precision robotic grippers pull the plate into position, guaranteeing precise register every time. Burgess’ register systems completely eliminate any dependency on the operator for accurate positioning of the plate, and ensure high levels of repeatable performance.

In-line or Off-line, Burgess Punch/Benders are the Finest in the World

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Burgess provides register continuity

from CtP device to plate on press.

Heres how it works...

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Burgess’ Electronic Robotic Tri-Point Pin Register System has proven to provide accurate and

precision register for any printing application. The Register System is used to register the imaged plate

within the punch/bender or shear prior to the punch/bend or shearing operation. The system design also

offers additional plate management quality tool options using CCD Camera Technology and image-

marks for on-line verification, detection, and correction, based on specific application requirements.

Plate Management Options: Added to the Electronic Robotic Tri-Point Pin Register System.

- ORV - Optical Register Verification/with one CCD Camera, used to verify the repeatability of the CTP

imaging device. System detects and verifies register. Plate is rejected if fails register verification.

- B-Opts Dual Register System/with two CCD Cameras used to verify the repeatability, and monitor

image tolerance of the CTP imaging device. System detects and verifies register. Plate is repositioned using

image-marks, if fails register verification. System provides dual register redundancy and system backup.

- Hole-Over-Pins For traditional analog film-to-plate applications and system back up to CTP.

The Burgess Register System...Performance Guaranteed!

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No More Damaged Plates - No More Slipsheeting

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Automated Sorting & Stacking of "Press-Ready" PlatesFlat Plate Stackers

As the plate exits the processor, the conveyor is energized and the plate moves into the stacking position. Once in the stacking position, the stack-er arms fl ip the plate, emulsion down, onto the transport cart. Each cart can hold up to 150 fl at plates. Additional carts can be used for storage, staging or continuous transportation.

Sorters/Stackers Stations

Plate scratching is a common problem that occurs with traditional manual sorting, stacking, and transport of “press ready” plates. Burgess has de-veloped multiple plate management options to minimize or eliminate this issue when automated plate delivery direct to press-side is not a viable option. Automated plate sorter-stacker stations are available in a variety of models and confi gurations.

Single Level Sort-Stacking Stations

A plate travels along the sorter-stacker transport modules on protec-tive wheels until it reaches the correct bin/cart. The sensor triggers the wheels to drop, placing the plate on delivery belts which transfer the plate into the appropriate stacking bin/cart on either the left or the right. Each station comes standard with two bins/carts that hold 16 to 20 plates depending upon size and bend geometry. Pop-up pins square the plate on each transport module along the way. Optional bin/carts with wheels are available for fi nal transport to press. Any number of single level sort-stacking stations can be linked together.

Dual-Level Sort-Stacking Stations

Dual-Level Sort-Stacking Stations are iden-tical to the single level sort-stack stations in design and function, but are stacked two high; the lower level at 24” and the upper level at 48”. The upper and lower levels are fed by a vertical multi-level plate transport indexing unit. The stack bins are fi xed to each sort-stack station. Any number of dual-level sort-stacking stations can be linked together.

Plate Indexing with Mobile Carts

Plate Indexing Systems with Mo-bile Carts are designed for use where plate handling is diffi cult because of space constraints, very large plate size, or slip-sheeting for protection of one plate from another in transport is a standard procedure. The plate indexing system delivers each punched/bent “press ready” plate into its own plate shelf in a mobile in-dexing cart. Plate shelf design is based on plate geometry to maximize the number of plate shelves per cart. Once full, the cart is removed from the indexing system and replaced with an empty one. The mobile cart is then wheeled press-side where the press operators hang the plates on press. The carts provide maximum protection, organization and storage at the press.

Plate Elevators

Burgess has designed and manufactured several different styles of elevator systems to facilitate automated plate delivery of “press ready” plates to anywhere in your plant. The elevator style selected is determined by several factors, such as the plate volume needed to be delivered and the distance and height up or down that the plates need to travel.

Plate elevators can range from simple four foot high vertical multi-level plate transport indexing elevators feeding dual-level plate highways, or dual-level

sort-stack stations to single bar elevators, or high speed elevator highways that cover multiple stories deliver-ing plates to upper and lower press decks.

Elevator components are made using the same preci-sion optical sensors for go/no go operation, non-stick protective (standard and heat resistant) belts, and rubber coated wheels for optimal control and protec-tion of imaged “press ready” plates as our other plate management modules.

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The Bugess Plate Manager (BPM)

Pre-Press Line 1

Line 2Line 1 Line 3 Line 4 Line 5 Line 6

The Bugess Plate Manager (BPM)

Pre-Press Line 1

Line 2Line 1 Line 3 Line 4 Line 5 Line 6

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The Burgess Plate Manager

provides Total System Control

for System Integration and “On-Command” Management of your Burgess

Fully- Integrated, Automated Plate-Lines. System creates a command “Control

Center” to manage, monitor and control Plate Flow, System Operation, Alarm

and Detection, Preventative Maintenance, Remote Control, Trouble-Shooting,

Programming, With or Without Web-Base Capability and Database Reporting.

Each supervisory system is custom-configured, based on the number of presses

and/or plate management lines.

The Burgess Plate Manager Supervisory System

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Modular in Design...

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The POWER of AUTOMATION

Custom Configured for Any Application

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10

Challenge Us!

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923

Commercial

Plant

Audit

Customer

Acceptance

Single P.O.C.

Portal Website

Release to

Manufacturing

System

Installation

Newsprint

Burgess Industries

takes responsibility for

and manages the project to

completion

Project Management

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We'll listen, roll up our sleeves, consider all the options,

use all of our experience and provide you with the mostcost-effective solution.

Call Us!

1-800-233-2589

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The Burgess Plate Management & Handling Product Line

Contact Burgess for a free

comprehensive plant audit.

We are proud to design and build our products in the USA.

Plate Transport

> “Lift-Up” Entry Conveyors > Dual-Level Plate Highway > Multi-Directional Transports > Bi-Directional Belt Transports > Crossover Conveyor Bridges > Plate Rotators > Dummy Plate Loaders > Automatic Plate Feeders

Plate Bending and Forming

> CTP Auto Bender > SuperBender™ > Auto News Print Bender (ANP) > Semi Auto News Print Bender (SANP) > Single End Bender > Sheet Fed Bender > Plate Punching, Corner Cutting, and Notching > Plate Shear

Plate Sort, Stack, and Delivery

> Plate Pods > Plate Elevators > Flat Plate Stackers > Single and Dual Level Sort-Stacking Stations > Stacking Carts > Indexing Units > Mobile Indexing Carts

Plate Management

> The BPM™ (Burgess Plate Manager) Workfl ow Control System > “On Command” Bar Code System > ORV - Optical Register Verifi cation Quality Control Tools > “Image Patch” Plate Inspecter Quality Control Tools > Remote Diagnostics > The BII “Service Eye”

Reporting Includes:

> Shift Reports > Preventive Maintenance reports > Uptime reports > Database for statistical analysis > Maintenance and historical reporting

Contact Burgess for Register Control Boards, Control Pins, Accessories, and Replacement Lamp Needs.