First DUPLO DSM-1000 installation in the Czech Republic and Central Europe
Published:
Tiskárna Kleinwächter has expanded its technological capabilities with a DUPLO DSM-1000 automatic die cutter. This is the very first installation of this machine not only in the Czech Republic, but also in the entire Central European region. The new technology will help the printing house accelerate production, improve safety and expand its ability to process jobs up to B2 format.
A family-run printing house with more than 30 years of tradition
Tiskárna Kleinwächter is a family-run company based in Frýdek-Místek, with a history dating back to 1991. From its beginnings as a small team of enthusiasts, it has gradually developed into a modern printing centre combining traditional craftsmanship with contemporary technology.
Today, the company provides services ranging from graphic design and offset and digital printing to comprehensive print finishing and bookbinding. It handles everything from individual author copies and personalised printed products to larger print runs of books, magazines, catalogues, municipal newsletters and corporate materials.
Investment in technology that enables the company to respond flexibly to changing customer requirements has long been an integral part of its development. The acquisition of the new DUPLO DSM-1000 automatic die cutter is another step in this direction.
Die cutting under increasing time pressure
Today’s printing companies face growing pressure to shorten turnaround times, manufacture short runs efficiently and reproduce previously completed jobs quickly. Die cutting can be one of the more time- and labour-intensive stages of the finishing process.
Until now, Tiskárna Kleinwächter had also carried out die-cutting jobs on older machines. However, operating them required experienced staff and, from the perspective of current production requirements, they no longer provided an adequate level of automation or safety.
The new technology therefore had to meet several important requirements: accelerate production, particularly for repeat jobs, simplify operation, gradually replace older machines and increase the maximum sheet format to B2.
The solution was the DUPLO DSM-1000 – Duplo’s first automatic B2 die cutter.
The first DUPLO DSM-1000 in Central Europe
The installation at Tiskárna Kleinwächter represents an important milestone. It is the first DUPLO DSM-1000 to be installed not only in the Czech Republic, but anywhere in Central Europe.
The machine is designed for automated die cutting of short and medium runs where rapid make-ready, high precision and the cost-effective production of frequently changing jobs are essential.
The DUPLO DSM-1000 uses conventional cutting dies and performs die cutting, creasing, perforating and kiss cutting. It processes sheets with a maximum size of 530×750 mm and materials with a weight of up to 600 gsm. Its maximum cutting pressure is 40 tonnes.
With an output of up to 3,000 B2 sheets per hour, it can significantly accelerate production, particularly for repeat jobs that also benefit from the rapid retrieval and preparation of stored settings.
Automation shortens job make-ready times
One of the machine’s main advantages is its high level of automation. Setup is managed through a PC controller, and a new job can be prepared in approximately five minutes. The machine has been designed for intuitive operation without requiring lengthy training for specialist operators.
The optional separation unit automatically separates finished products from internal and external waste. Production therefore requires fewer manual interventions, allowing the operator to focus on process control and preparing subsequent jobs.
When processing digitally printed sheets, cameras read registration marks and compensate for potential variations in image position, helping maintain accurate die cutting.
The DSM-1000 also offers a multi-cut mode in which the machine can perform up to three pressing cycles on a single sheet using the same die. This makes it possible to use smaller cutting dies efficiently, optimise sheet utilisation and, in some cases, reduce die manufacturing costs.
New opportunities for packaging and shaped printed products
The DUPLO DSM-1000 opens up further opportunities for Tiskárna Kleinwächter in the production of packaging, folding cartons, presentation folders, greeting cards, envelopes, shaped printed products and POS and POP materials.
The production of packaging in short and medium runs represents a particularly significant opportunity. These jobs require a combination of high die-cutting quality, rapid make-ready and economical production of quantities that might not be efficient on conventional high-volume equipment.
The new technology will therefore allow the printing house to respond more flexibly to demand for shorter runs, original shapes and packaging solutions with higher added value.
Jan Kleinwächter: We expected speed, safety and a larger format from the new machine
We spoke with Jan Kleinwächter, Managing Director of Tiskárna Kleinwächter, about the reasons behind the investment and the company’s initial experience with the new technology.
What were the main reasons for purchasing the DUPLO DSM-1000?
“There were several reasons. Pressure on production deadlines continues to increase, and we expect the DSM-1000 to deliver a significant improvement in speed, particularly for repeat jobs.
At the same time, we want to gradually discontinue die-cutting production on our older machines. They are more demanding to operate, while the new machine also provides us with a higher level of safety.
Another important factor was the ability to increase the maximum sheet format to B2.”
How has the DUPLO DSM-1000 moved your production forward?
“Our die-cutting production has become simpler and significantly faster for repeat jobs. At the same time, new opportunities are opening up for us in the production of packaging in short and medium runs.
Our experience so far has met our expectations – from ease of operation to die-cutting accuracy and quality, as well as production speed.”
Technology ready for a changing market
The installation of the DUPLO DSM-1000 reflects the changing demands placed on print finishing. A growing number of short-run jobs, shorter production deadlines and increasing demand for original packaging are making technologies that combine automation, rapid make-ready and high precision increasingly important.
For Tiskárna Kleinwächter, the new machine is not only a replacement for part of its older equipment, but above all another step in the development of its production capabilities. It delivers simpler and safer die-cutting processes, higher productivity for repeat jobs and new opportunities in the packaging and shaped print segments.
The first DUPLO DSM-1000 in Central Europe is therefore entering production with a clear objective: to help the printing house manufacture faster, more safely and in a larger format, while creating space for jobs that could not previously be processed with the same level of efficiency.