BANKNOTE HORIZONS 2016 SPECIAL - KBA-NotaSys SA...KBA-NotaSys developed thePlateGrind II machine in...

N°10 AUTUMN I WINTER 2016

The KBA-NotaSys magazine about banknote design, production and circulation

BANKNOTE HORIZONS 2016 SPECIAL

Banconota, the magazine about banknote design, production and circulation, is published

by KBA-NotaSys SA for its clients and business partners.

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or for any other communication, please use the details below:

CONTENTS BANKNOTE HORIZONS SPECIAL

Graphic design: Emilie Fargues - emkidesign

Pictures: Giulio Locatelli: 3 (top), 4, 11, 12, 13, 14, 15, 17, 18 (top), 20, 25, 26, 27

Sébastien Staub: 3 (bottom), 19

KBA-NotaSys: 16, 18 (bottom), 20 (top), 21, 22

Editorial Support: Stéphane Maillot

Printer: Courvoisier-Attinger Arts graphiques SA

© 2016 KBA-NotaSys SA All rights reserved. Reproduction in whole or in part

without express permission of the publisher is prohibited.

04 DAY ONE // MORNING Total Cost of Ownership

Cash Cycle and Pre-press

14 DAY ONE // AFTERNOON Machines Demonstrations and Workshops

17 DAY TWO // MORNING Flexible Finishing

Quality Control Solutions

Management Information Tools

Security Printing

23 DAY TWO // AFTERNOON Counterfeit Deterrence

Efficient P oduction

Training and Services Support

KBA-NotaSys SA

Banconota Magazine

PO BOX 347

CH-1000 Lausanne 22

Switzerland

[email protected]

Fax: +41 21 345 70 10

Phone: +41 21 345 70 00

BANKNOTE HORIZONS 2016

Dear readers,

It is with great pride and pleasure that we present you this new edition of our Banconota magazine which is completely dedicated to our Banknote Horizons event that we hosted in June of this year. If you were among the more than 300 customers and partners that attended the show, this will be a great reminder of the two days you spent with us and will help to refresh your memory on the many things we have discussed. If you were not in Lausanne in June, this will give you a great insight into the novel developments that were presented.

Banknote Horizons saw the launch of several new technologies and demonstrated the coming of age of some of the prototypes we had shown at the event in 2012. It was now possible to demonstrate that the full job-change on the Super Simultan IV can be done in less than 2 hours and that the increased registration enables the creation of a whole new range of security features like the SUSI Flip™ and SUSI Optics™. We also showed the significant ink savings on the Super Orlof Intaglio thanks to the automatic adjustments of the chablon cylinder, allowing for a finer cut of the inking chablons. All the developments and their impacts are best found through our Total Cost of Ownership calculation model which was presented for the first time in June. We have been and are working with various customers on making their specific calculation and invite you to learn more about it in this edition.

We wish you a lot of reading pleasure and look forward to meeting you again soon.

With very best regards,

Gerben B. van Wijk, Marketing and Communication Manager

Dear readers,

We were delighted to welcome some of you to Banknote Horizons 2016 in Lausanne.

Ever since we were founded in 1952 our goal has been to support countries worldwide to produce their own banknotes.

As those who attended have discovered, our environment is ever-changing, with new security challenges and new innovations shaping the path forward. At KBA-NotaSys, we are committed to continuing to lead from the front, helping you to meet all your banknote creation and production needs, wherever you are in the world.

During our event, you have seen the launch of a new visual and verbal identity for KBA-NotaSys which will be reflected in all our communications moving forward. We are confident it will allow us to communicate far more effectively and help reinforce that KBA-NotaSys is your ideal high security partner – today and tomorrow.

Value Beyond Technology becomes our new tagline, succinctly underpinning the way we will endeavour to do business moving forward. Leading-edge high security technology will continue to be central to our offering but the decades of know-how we bring, and the dedicated support we strive to offer – through the lifetime of our relationship – add up to a value far greater.

You will see this sentiment embodied within our new corporate brochure and, I firmly believe, in all our future interactions.

With kind regards,

Eric Boissonnas, CEO KBA-NotaSys

DAY ONE

DAY ONE // MORNINGCash Cycle and Pre-press

DAY ONE // AFTERNOONMachines Demonstrations and Workshops

AUTUMN | WINTER 2016 Banconota

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EFFICIENT SECURITY

For most visitors, the event lasted two full days during which they had the opportunity to discover, under the guidance of our specialists, the latest developments of our products and services.

The programme was designed to drive participants through the various stages of banknote production, from conception to after-sales services.

In a world where the average lifespan of a banknote series has dropped from 18/20 years (and more) to 7/9 years, in an art where design meets process, in an industry where technology becomes an everyday challenge... our ‘Total Cost of Ownership’ approach will help you create additional security without creating additional costs, while at the same time improving overall efficien y.

You might already ask yourself daily: • What are the cost drivers in banknote production? • How much does this equipment cost? • How much does it cost to run this equipment?

And you probably realise that buying a machine or investing in a process is not all and you need to go beyond that.

Considering the overall cost of running a process over the years is the key you are looking for. Calculating YOUR Total Cost of Ownership will be a powerful tool to assist you in the decision making process.

Our ‘Total Cost of Ownership’ approach will help you evaluate the financial implications versus the lifespan of a technology and assist you in the understanding of cost allocations (consumables, substrates). This tool is designed to help you make well informed decisions when it comes to capital investments. It is based on a calculation of your real cost of production taking into account all your specific technical and human parameters

The ‘Total Cost of Ownership’ approach will help you to answer the following questions:

• How am I currently organised?• Where can I increase my efficiencies• What would implementing new technology mean to my operations?• How can KBA-NotaSys help me?

Our specialists will be more than happy to assist you in making the Total Cost of Ownership calculations based on your specificparameters. Contact your Regional Director for more information.

TOTAL COST OF OWNERSHIP PRESENTER: PHILIPPE MONTÉLIMARD

Banconota AUTUMN | WINTER 2016

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CASH CYCLE

IMPORTANCE OF INTEGRATED DESIGN AND CASH CYCLE FUNCTIONALITYPRESENTERS: VINCENT MOREAU AND JÜRG HOFMANN

They started off by by asking the audience about the level of security of banknotes in their cash cycle and the risk that counterfeited banknotes might be accepted by the public or banknote handling machines (BHMs).

This risk is very real and the presenters showed a recent and vivid example: the Hong Kong dollar 1’000 series 2003. This banknote is co-circulating with its replacement the HKD 2010 series, which represents a much higher level of security and was therefore not affected at all. The overall characteristics of the counterfeited notes were of high quality and they could have been mistaken as genuine by the public. More worrying was the fact that the counterfeits were accepted in a number of cash deposit machines in Hong Kong.

This counterfeit incident rushed the withdrawal of all different designs of the 1’000 of the 2003 series from circulation. The Hong Kong Monetary Authority (HKMA) held conferences and press releases were made to explain the situation with transparency from the beginning. Education of professionals (bank tellers, retailers) was reinforced and information on counterfeiting was made available to the public via different communication media.

Specific actions were taken in partnership with the BHM suppliers with regards to a thorough authentication of all machine readable features. First, an operational analysis of the BHMs was conducted. Ultimately, it showed that not all the machine readable features were checked to its highest extend when a banknote was processed. Thanks to a good communication between the stakeholders, the gaps could be identified and successfully closed within a short time.

Once the situation was better understood, the BHM suppliers were educated on the risks and forced to set an improvement

of the level of security of the authentication of banknotes in the Hong Kong cash cycle. Finally, the BHMs were modified and re-calibrated to reinforce the security against counterfeits. In this specific case, the Hong Kong Police even provided the counterfeit notes to help with the necessary re-calibration.

Even though a low number of these high quality counterfeits was found to date, it is an opportunity for each country and central bank to reflect on the quality of the level of security of their banknotes in circulation and especially to understand which security features are checked by the public and the BHMs. Vincent Moreau and Jürg Hofmann used their presentation to ask visitors:

• Of all the machine-readable features in your banknote, how many of them are read by machines, and how often?

• What implementation plan is in place to ensure that the machine-readable features are checked by the machines?

• What are the considerations for choosing a new machine-readable feature for a new notes series?

More and more counterfeiters are manipulating banknotes, which are even more delicate to distinguish by the public and also by the BHMs. This reinforces the need to know thoroughly your Cash Cycle and to have as much control as possible on its stakeholders to influence the parameters and maintain security at an optimal level.

The presenters concluded by recommending the audience to follow a holistic approach when creating new banknote series, with a standardized system of security features and the artistry integration of the iconographic material in the functional layouts from the beginning of such a challenging project. This means combining equally the security (high resistance against counterfeiting), the functionality (managing the artistic and functional aspects of the design) and the printability (optimised productivity).

After the initial welcome and introduction, the journey started with a presentation from Vincent Moreau (Banknote Services Manager) and Jürg Hofmann (Cash Cycle Services Manager).


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The creation process of a new banknote is complex and requires a lot of steps: Alexander Fellmann demystified it by presenting how we developed our new specimen series named Generation. It all starts with the requirements. To demonstrate the range of our capabilities, it is important to test all the possible production processes while at the same time respecting the cash cycle functionality. This was the rationale behind the decision to create 3 different denominations: a low, middle and high value, as is often seen in actual currencies.

For each process, the teams are asked to challenge themselves and to push back the limits of printing.

The Design process starts with the choice of a theme (i.e. life of mankind) that is developed to showcase:

• specifications (possibility to print the same design on different substrates such as Cotton, Hybrid or Polymer)

• security features of all major processes (Offset, Foil-Application, Screen, Intaglio, Numbering, Varnishing)

• substrate features (such as watermark, security thread, windows…)

• print features (for example Susi Flip - a new feature in the Simultan process- , latent image, special inks…)

• integration of a foil

What makes a design successful? According to all our teams, it is the match of artistry and functionality which come together together in a specific overarching theme under a common design language. In a functional layout all relevant security features are defined and linked with the design elements in an elegant and meaningful way in which they comply with the needs and restrictions of the local cash-cycle.

After defining the theme and specifications, ‘origination’ begins. Origination is the translation of the concept from sketch to a fully printable security document.

Let’s focus on our low denomination specimen. It represents Childhood (birth, children playing, spring time…) and contains representative elements translated into the various features.

To prepare the banknote draft, the security designer transforms the chosen images into printable line patterns. The result is a collection of structures, which can be used as generic elements for our ONE software.

A flower becomes a printable line design (1) that can be combined and multiplied to create patterns (2) and then included in the banknote design (3). The designer follows the same process for the features development (See Through, SPARK Live, Watermark…).

(1)

(2)

(3)

PRE-PRESS

OUR NEW SPECIMEN SERIES: ‘GENERATION’PRESENTER: ALEXANDER FELLMANN


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The See Trough has the shape of a flower bud (4), the SPARKLive feature is inspired by the bubbles that are seen in other parts of the sign of the reverse of the note (5), the watermark was based on blossoms (6) and the laser-cut was inspired by the honey bee (7).

“When we prepare a new specimen series, we always make sure that we challenge every team participating in the process to implement the latest innovations at our disposal.” Alexander Fellmann, Security Designer

All placed together it results in the low denomination Generation specimen of which you can see the front and reverse here.

(4) (5)

(6)(7)


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The ONE Security Design Software is the backbone of the design process. It is used to create your security documents by ‘translating’ the artwork into printable designs and security features (‘origination’ process.)

ONE is dedicated to the creation of high security documents such as banknotes, passports, stamps etc. It supports banknote designer in the creation and assembly of all types of elements and printing processes. In particular the engraving depth and shape parameters for the Intaglio elements are fully controlled. ONE is based on the unique experience and know-how of the different security printing processes that KBA-NotaSys developed over several decades.

The ONE software is under constant development and new versions are released every year. Since the Banknote Horizons event in 2012, four versions have been released with the following main features:

• SimMark Generator (v1.5 2013): generates SimMark®

security elements which require the precision of the latest Super Simultan press

• Grid Warp Editor (v1.6 2014): allows the warping based on user-defined grids of any kind of line work

• Divide Module (v1.6 2014): is used to emphasise the SUSI Suite capabilities, by creating multi-colour patterns which require a perfect registration between all colours and plates

• Geometrics Generator (v1.7 2015): generates fractal and recursive patterns in one or several colours

• StyleArt-Pro Generator (v1.7 2015): generates complex patterns based on user-defined shapes with an extremely high level of interactivity. The control of the width of the lines and its modulation (‘calligraphy’) is fully supported

• FillArt-Pro Generator (v1.8 2016): creates unique pat-terns based on random repetition, scaling and rotation of user-defined shapes. Series of different sequences can be added in order to get dense and unique backgrounds

Make sure you never miss a new feature: join our “Jump ahead – Stay ahead” programme and get automatically every year the latest version of your software. You will also benefit from training and refreshing courses as well as support based on your needs.

µ Multi-shape bakground generated by the new FillArt-Pro tool

µ StyleArt-Pro element with calligraphy

µ SimMark and See-Through elements for SuperSimultan press

PRE-PRESS

LATEST FEATURES OF ONE® SOFTWAREPRESENTER: LAURENT MATHYS


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PLATEGRIND II – THICKNESS IS KEY FOR INTAGLIO PLATESOne of the most important and sensitive steps in the manufacturing process of intaglio plates is the grinding of the back of the printing plate. Uneven thickness can generate huge problems when printing and a poor quality could even damage the Plate Cylinder.

KBA-NotaSys developed the PlateGrind II machine in collaboration with the Swiss company Studer, one of the market leaders in cylindrical grinding machines.

The PlateGrind II is a compact, fully automated machine with a well dimensioned footprint, specifically developed for grinding intaglio printing plates.

The main advantage of the PlateGrind II is that it uses successive plunges for rough grinding followed by longitudinal grinding for finishing. This makes it possible to minimise the negative influence of the inevitable differences in electroplating thickness and results in significant time saving compared to conventional, longitudinal grinding.

A further advantage of the machine is that it works fully automatically once the grinding cycle has started: it manages on its own the initial and intermediary measurements before the finishing cycle, as well as the final measurements of 6 clearly specified points.

The frame of the PlateGrind II is made of epoxy granite called Granitan® which guarantees outstanding thermal and dimensional stability, as well as excellent dampening properties.

The flat and V-shaped guideways for the longitudinal and cross slides are moulded directly into the machine base and are provided with a non-abrasive Granitan® side-way coating for resistance to wear. The guideways offer the highest possible accuracy through the entire speed range with high load capacity and cushioning levels. The non-magnetic machine bed is optimal, especially for linear motors.

The objective of having perfectly ground Intaglio plates is fully achieved with this machine. It complies with the expected thickness and roughness tolerances of + 5 μm and Rz < 4 μm set by KBA-NotaSys and confirmed by many customers.

PLATECOAT – MOVING AWAY FROM CHROMIUM VIWorldwide regulations have been strengthened and Chromium VI will soon be banned from industrial processes. As Chromium VI is present in galvanic chrome baths they will have to be replaced by a Chromium VI-free solution.

During the previous Banknote Horizons event in 2012, we presented a revolutionary prototype, the PlateCoat. The machine, using Physical Vapour Deposition (PVD), was the first step towards a better and safer way to coat intaglio plates with chrome, without any Chromium VI present in the process.

The PlateCoat is now a fully industrial product which has already been adopted by the Canadian Banknote Company, the National Bank of Ukraine and the Banque de France.

The full process runs under vacuum and requires a clean environment. This is the reason why the PlateCoat is linked with a clean room which offers a dust free area to prepare the plate. The plate is loaded and the process starts with the plasma etching. It is a surface cleaning of the plate under vacuum to facilitate the adhesion of the coating on the nickel plate. This is followed by the chrome deposition in 2 steps: first a pure chromium layer (2μm), followed a chrome-nitride layer (2μm). This last layer is harder than the pure chromium layer.

The whole process is completed in 90 minutes. It is fully automated and monitored. The system alerts the operator when a deviation occurs during the process and the operator can take the required action: abort, repeat or resume part of the process.

The advantages of this new machine compared to the galvanic chrome bath system are very significant: Chromium VI is fully eliminated from the process, it is easier to use, and the plate life-span is increased thanks to the hardness of the chrome-nitride layer.

This year, the tour of the pre-press department focused on two machines, PlateGrind II and PlateCoat, and on process control.

PRE-PRESS

TOUR OF THE LATEST DEVELOPMENTSPRESENTERS: MICHEL SCHECK, YANN VEGUER AND JACQUES PERRIER


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PRE-PRESS TO PRESS PROCESS CONTROLHigh security offset patterns require the highest precision, meaning the highest registration between printing units as well as the highest definition on the printed lines.

To achieve this, the full process from the pre-press (design and platemaking) to the press (plate mounting, plate-blanket interaction and other mechanical aspects) needs to be controlled and understood to optimise the printing results.

KBA-NotaSys can now offer very high precision verification of your pre-press and printing processes thanks to an extremely precise metrology equipment and data analysis. The precision of this dedicated equipment is a couple of microns over the plate or sheet area.

During Banknote Horizons 2016, Dr Jacques Perrier, Senior Product Manager, demonstrated the use of the equipment on a wet offset plate. Analysis of the measurements produced a distortion map (deviation from the nominal position) and led to a method of adjusting and improving the printed outcome.

The PlatePunch IV and PlateBend pre-press devices are integral parts of the Super Simultan IV high-precision-clamping solution. They are controlled and adjusted with the highest precision using the same metrology equipment.

Printed sheets can be measured as well and the behaviour of the different substrates determined when they pass through the press. This behaviour is important to understand as it directly affects the registration between the upper units and the central units of the Super Simultan IV and, as well, the registration between the offset and intaglio printed patterns.

In addition, the relative registration between printing units can be deduced and linked to the press properties.

Once relative registration and printed line properties (width, raggedness, blurriness) are quantitatively measured they can be used to predict beforehand how security patterns will look like once printed. Security patterns can thus be adjusted to maximize security while still being printable.


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SUPER SIMULTAN IVThomas Kersten, Product Manager for Offset printing machines, started the machines demonstrations by presenting the Super Simultan IV and its brand new features. This machine, the 19th of the series, is already known for its high precision simultaneous offset printing capabilities. To unveil one of our latest achievements, visitors were invited to stop by the machine just before the tour of the Pre-press department, to witness for themselves that it was printing our new Generation Low Denomination specimen. In a short speech Thomas announced that the instructors would perform a job change-over in less than 3 hours. So basically the machine would be ready to print the new Generation High Denomination specimen early afternoon, once visitors would be back from lunch.

You might wonder what a complete job change-over is. The instructors start by cleaning the whole machine. Then they exchange all 10 printing plates and fill in the 20 reservoirs of the ink fountains with specified inks. After this, they launch a first print and check the balance for each colour. Due to the high quality demands of the New Generation specimen, an optimisation of the colour register is carried out before being able to launch the new production.

To make sure time was tracked, a large clock was installed above the machine. Each day, instructors usually managed to implement the complete job change-over in a little more than 2 hours. But on Wednesday, June 15th, it took them only 1h58mins to go from the Low Generation to the High Generation denomination! A few days later, they even managed to print in a perfect colour balance and registration in less than 1h39mins, proving that thanks to our newly developed and award-winning* semi-automated plate-clamping device, a complete job change-over can become a time-saving activity. With less downtime and an improved accuracy, the Super Simultan IV drastically enhances productivity.

The exceptional performance of Super Simultan printing will be guaranteed by observing all intermediate procedures for print job preparation and execution. KBA-NotaSys describes this procedure as SUSI Suite Workflow. It is a holistic approach to plate making, plate preparation, plate handling and Simultan Printing itself.

KBA-NotaSys can assist you in each of these steps. Controlling the SUSI Suite Workflow is the key to success!

SUSI FlipTM

SUSI FlipTM is an advanced fluorescent security feature taking advantage of the latest SIMULTAN offset printing technology. It combines two to four UV colours allowing a complete switch between the daylight image and the UV designs. The sole presence of UV fluorescence is, in some cases, too easy to simulate. The approach of SUSI Flip™ is to fully exploit the precision of the SIMULTAN offset printing process, creating an easily authenticated level 2a feature that is virtually impossible to reproduce using commercially available technologies. If the design is done appropriately, any 2 dimensional macroscopic structure will be transformed into any other 2 dimensional structure under UV illumination.

SUSI OpticsTM

SUSI Optics™ is a LenSys Sàrl feature developed in partnership between Lumeco Inc. and KBA-NotaSys SA. This highly secure feature combines a circular micro-lens structure with interlaced simultaneous offset printing on note fronts and backs in at least two colours in perfect register to exploit the high precision of the SIMULTAN process.

SUSI Optics™ is an advanced security feature which makes it possible to create a multitude of advanced interactiveeffects including movement on the horizontal and/or vertical axis, 3D effects, the sensation of depth, colour shifts, the transformation of shapes, or any combination of these effects. The feature size and design are completely flexible as are the types of effect.

MACHINES DEMONSTRATIONS

WHAT’S NEW SINCE 2012?PRESENTERS: THOMAS KERSTEN, ALAIN WÜRSCH, AURÉLIE BERTHON AND EMMANUEL THONY


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*: KBA-NotaSys won the International Association of Currency Affairs (IACA) 2016 Technical Excellence in Currency Award.The award was attributed to our new automated plate-clamping device, which allows printers to introduce new and innovative features in the offset design, and also reduces set-up times and waste.

Other features presented include:• The new range of security features including SUSI FlipTM

& SUSI OpticsTM requiring a stable and amplifying process [cf. insert]

• The new ColorSaveXT with ColorCheck Simultan (more on page 20)

SUPER ORLOF INTAGLIO IIIDuring Banknote Horizon 2012, we unveiled the Super Orlof Intaglio III prototype. Since then several machines have been installed all around the world and we have kept improving it to answer our customers’ needs.

As cost is a crucial aspect of production, this press integrates many unique features to achieve lower production costs:

• Saving time: a feature highly appreciated by our customers is the semi-automatic wiping cylinder exchange. Thanks to this two arms mechanism, the heavy wiping cylinder can be directly transferred to the trolley. A full exchange of the wiping cylinder is done in less than 4 minutes in a very safe manner, where 10-15 minutes were needed with the older crane solution.

• Reducing ink consumption: ink represents more than half of the production costs in intaglio printing. We are proud to present you with our new plate length elongation compensation system linked to our unique 3-3-3 configuration, where each blanket always inks the same intaglio plate. During the production, due to the very high pressure imposed, intaglio plates slowly elongate up to around 1mm over their life span. To guarantee the inking of all the engravings during the lifetime of the intaglio plate, the chablon plate normally requires a cut 0.8mm to 1mm larger than the intaglio engraving, a lot of unused ink is then wasted by inking areas of the intaglio plates without engravings. With the new plate elongation compensation system, we can adjust the length of inking to match the length of the intaglio plate during production. This allows the chablon cut to accurately fit the size of the engraved design. With such a narrow cut, less ink is consumed, the demonstrations during Banknote Horizons showed an ink saving of up to 25%.

• Fitting your LEAN approach: we are developing a new control console to improve its ergonomic. Operators will benefit from an easier and faster access to all available information and tools necessary for their work. During the Banknote Horizon 2016 presentation, we asked visitors to participate in the development of this new feature by sharing with us their thoughts and feedback. If you are interested in knowing the outcome of this survey or sharing your input, do not hesitate to contact us.


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NZ$10 banknote printed on a polymer substrate: it features

the SPARK®Live ink and a holographic patch in a polymer window. Ô

• Reducing waste by detecting defects earlier: The Super Orlof Intaglio III is equipped with our latest generation of inspection system, the NotaSaveXT. The NotaSaveXT is our 4th generation of 100% inline inspection system, harnessing our 20 year experience of intaglio inspection. It has the new AFX-II inspection technology with more than 10 times the processing power of the previous AFX, which allows full high resolution image inspection and the implementation of more sophisticated algorithms.

• This system has a higher resolution, no image distortion, homogeneous illumination and a better colour response. It allows detecting finer defects, such as wiping lines and can even perform register measurement between printing processes. The live image is displayed on an ultra-high definition screen for easier communication with the quality control specialist and the printers, and a high definition touchscreen monitor allows control of the system.

NOTASCREEN IIThe NotaScreen II is a dedicated banknote specific screen printing machine. It is able to print any type of security screen inks including customer specific ink. Since 2012, we have kept improving it and working together with our partners to enhance its security printing capabilities.

• Increased ink security: in 2014, a new generation of SPARK® was launched: SPARK®Live. The NotaScreen II is the only machine on the market capable of printing the SPARK® feature. Once the ink has been deposited, the position of pigments is fixed while they are perfectly aligned in the magnetic field, creating the dynamic effect. In order to fix the orientation of pigments of OVMI® inks, the machine needs to be equipped with the SPARK Inline UV Dryer.

• Better screens lifespan: our new squeegee system is now installed as a standard on the current NotaScreen II series. It allows lifting up and setting back the squeegee in a user-defined timing, which helps limiting the pressure applied on screens, thus increasing their lifespan.

• Improved process and quality control: The fully integrated ScreenSaveXT® system with its colour line scan camera keeps a constant guard over print quality and will immediately alert the operator to any defect.

OPTINOTA HThe OptiNota H is the only machine available on the market that has the capability to apply OVD foil in form of a stripe or patches, as well as cut windows in the paper and apply a lamination stripe on top. This step of the application process usually happens between the Offset and Intaglio processes, maintaining the overall production pace thanks to its 10’000 sph capability.

The main improvement of this machine in the past four years is the development of a new counter pressure system. The 6 rows of rollers have been replaced by 3 cylinders, which are driven by motors, leading to a better sheet transfer at the stamping unit. Each cylinder is equipped with individual rings that can be adjusted laterally to fit the sheet layout. The circumference of each ring equals the length of a segment on the stamping cylinder, so that each ring will always touch the same area on the substrate. The result is fewer flakes and fewer markings on the substrate.

This system is especially interesting for patch application on polymer windows, greatly improving the quality of foil application and patch contour.


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DAY TWO

DAY TWO // MORNINGFlexible Finishing Quality Control SolutionsManagement Information ToolsSecurity Printing

DAY TWO // AFTERNOONCounterfeit DeterrenceEfficient P oductionTraining and Services Support


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The Numbering and Finishing equipment was the last to be presented during the machines demonstrations. Matthias Gygi, Senior Product Manager, showed the Check NumeroProtecta, a combined sheet inspection, numbering and varnishing machine, and detailed its main features. It is equipped with UV dryers to cure serial numbers and the protective varnish layer minimising paper handling and work-in-progress.

The machine is equipped with our NBX numbering system, embedded in the master control station. This system enables you to define a large variety of numbering schemes and to optimize the subsequent finishing and packing processes.

Quality control is taken care of by the DataScan system to verify correctness of numbers and print quality. Magnetic features are checked thanks to the MagneticCheck device.

The Inspection module is perfectly integrated enabling full sheet inspection in all aspects up to the maximum machine speed.

An inline varnishing unit is also provided to obtain a fully integrated solution. This is the only way to process banknotes and obtain sequentially numbered and varnished sheets for the cutting and packaging process. Varnishing is mandatory when printing on polymer and hybrid substrates.

Matthias mentioned the KBA-NotaSys’ range of finishing solutions that was not available in our Lausanne showroom, like the CutPak III and CutLink X. These machines evolve with our latest innovations, and complete ideally the banknote production process in your print works.

FLEXIBLE FINISHING

EQUIPMENT DEMONSTRATIONPRESENTER: MATTHIAS GYGI


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Dragan Dragoz, Finishing & Numbering Equipment Product Manager, followed the machine demonstration with a workshop around the economics and new functionalities of Flexible Finishing.

The cost of the finishing process in the overall production costs of a banknote is usually considered to be around 10%. We can help you decrease this amount thanks to various solutions.

1/ NUMBERING PROCESSA solution to improve the efficiency of the finishing process is to implement smart numbering boxes. This allows the operator to pre-set the start number, pre-ink blocks and switch blocks through a user-friendly interface. The Mandatory Activity Time (MAT) is reduced and a 9% gain in efficiency is observed for a two shift work day (impact mainly on Labour).

Traditional numbering boxes require a dedicated collating process in and after the finishing equipment to assemble consecutively numbered notes, whereas the NBX system numbers printed currency sheets as required, providing bundles that can be directly packed in a box after finishing.

2/ INSPECTION SYSTEM AND SALVATION PRO-CESSWithout any integrated inspection systems, sheets have to be fully inspected before running through the numbering equipment. This necessitates having a large number of inspectors available to cover the production day and night.

On the Super Check Numerota III, the integrated inspection system is able to check the visual and machine-readable features on the full sheet and at machine speed (10’000 sheets per hour). The inspection system is composed of 4 dedicated drums (one is transparent for see-through features) and verifies visible, UV and infrared features on the front and the reverse of each sheet. Only defective sheets are inspected manually, requiring fewer inspectors and saving up to 23% of the finishing process cost. Partial waste can be numbered using an alternate scheme and defective notes can also be marked.

3/ UV CURING VARNISHING UNITA varnishing unit can be integrated in your finishing equipment (Super Numerota III). Using an in-line varnishing unit has numerous advantages: a reduced number of operators, less paper handling logistics, less space needed in your printworks, a lower risk to spoil numbered sheets and a reduction in paper waste.

Overall, we have calculated a 9% increase in cost efficiency.

Dragan concludes: “Choose a flexible finishing solution adapted to your need and improve your banknote printing process efficiency thanks to reduced labour costs, process time and material losses, as well as increased recovery rate.”

IMPROVING COST EFFICIENCY THANKS TO FLEXIBLE FINISHINGPRESENTER: DRAGAN DRAGOZ


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KBA-NotaSys demonstrated its new line of banknote inspection systems at Banknote Horizons 2016.

Mr. Thomas Türke, Senior Product Manager for Quality Control Systems commented:“We launched our new technology platform called AFX-II in spring this year and we were pleased to be able to show our customers the equipment fitted to the Super Simultan IV and Super Orlof Intaglio III in our demonstration hall.

Under the critical eyes of expert customers from around the world, we showed how the integration of touch based user interfaces, a large display and next generation quality algorithms allow the operator to get the best and most consistent quality out of his machine, day in, day out.

For example, combining the ColorSaveXT and ColorCheck table allows the operator to react more quickly to reduce quality drifts and keep registration on the Super Simultan IV within the banknote designer’s specifications.

Of course, validating the system concept is very important to us and we are grateful for the enthusiastic customer feedback and comments which has allowed us to improve some features. The results speak for themselves, more than 20 systems have been ordered to date.”

For further information on the dedicated inspection solution for each process, please refer to the appropriate product brochure available from KBA-NotaSys.

Table: New Product Names

Product Description

ColorSaveXT Inline inspection for Simultan presses

ScreenSaveXT Inline inspection for Screen presses

FoilSaveXT Inline inspection for OptiNota presses

NotaSaveXT Inline inspection for Intaglio presses

NotaCheckXT Final inspection for Numerota based machines (SuperCheck, SuperCheckNumerota, CheckNumeroProtecta, NumeroPak)

ColoSaveXT with integrated ColorCheck Simultan module µ

WORKSHOP

QUALITY CONTROL SOLUTIONSPRESENTER: THOMAS TÜRKE


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We all need to make decisions. This is especially true in the production of technically sophisticated banknotes.

As the various printing and processing machines are used to add value to the banknote, it makes sense to use data from the machines themselves to help drive decision processes.

Machine Data Center (MDC) is the bridge between the machines and decision support computer systems such as in-house systems, SAP, Microsoft AX, JD Edwards, Oracle and Parvis ABACO.

MDC makes it easier for in-house and ERP programmers alike to add process, production, quality and maintenance data into their decision support systems. It provides a standard data interface that hides the complicated machine details allowing valuable programmer resources to concentrate on in-house needs.

MDC provides data from all standard sheet fed machines as well as CutPak and CutLink. It also provides “data viewers” allowing operators and managers at the machine to see first-hand how processes, such as quality control, are developing in real-time.

MDC connects to• The machine control system for production and mainte-

nance data.• ColorSaveXT, ScreenSaveXT, FoilSaveXT, NotaSaveXT,

NotaCheckXT,DataScan ST and Magnetic Check systems for quality data.

• Machine sensors for process data such as temperature and pressures.

MDC stores data on the machine for up to 3 months and produces various reports in CSV and PDF formats.

µ The illustrations above are based on simulated data used for training purposes.

WORKSHOP

DATA DRIVES DECISIONSPRESENTER: KEVIN SMITH


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WORKSHOP

TURNKEY SOLUTIONS TO PRINT SECURITY DOCUMENTS PRESENTER: ROB STIERMAN

This year, we dedicated a presentation slot to our Passport and Security Documents expertise. We took this opportunity to showcase that KBA-NotaSys Printing technologies deliver the same security and high level print quality for the production of ID documents or Tax Stamps as what we deliver for the production of banknotes.

Rob Stierman, Product Manager for the Passport line, showed how our equipment can be used to produce Passports, ID Cards or Tax Stamps. He presented in detail how the production of such documents can be managed and included in a Security Printing plant, in parallel to banknotes to ensure you benefit from an integrated system.

Visitors were also presented with the beginning to end solutions provided by KBA-NotaSys with regards to security documents. These solutions encompass design with up-to-date security features, platemaking, printing and finishing solutions, adapted to each customer’s specific needs as well as to the production characteristics.

• Tax Stamps: Intaglio is still the most effective security fea-ture and can be produced thanks to our i-con or Mini Or-lof Intaglio III machines. We have various numbering and finishing solutions for stamps in reels or as single stamps

• e-Passports: We can offer the full production from design, cover printing and binding thanks to our partnership with Kugler Womako

• ID Cards: During Banknote Horizon 2016, we introduced the specifically designed Genius 52 for plastic printing which was recently added to the KBA-NotaSys portfolio. This press is already widely used for ID-card printing and for polycarbonate data pages in e-Passports (see insert)

We are here to partner up with you for of these security document solutions, so do not hesitate to contact us.

Genius 52 – Simply Ingenious

We integrated this new equipment in our portfolio shortly before Banknote Horizons 2016.Advantages:

• environmentally friendly thanks to its waterless offset printing system

• waterless printing also allows for very fine details thus enhancing the quality of the security features

• specifically designed to print on various sorts of plastic bu can also print on paper and even wood

• cost-effective for small production of ID cards and polycarbonate data pages in e-passports

• quick job change-overs• very low start up waste• easy to operate by just one person• rainbow printing and security inks• other possible applications for this press : bank cards,

driver licenses, national health-cards, voter cards…


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WORKSHOP

SUPPORTING YOU IN YOUR COUNTERFEIT ANALYSESPRESENTER: MATHIEU BRICHON

The afternoon of the second day started with our Head of Anti-Counterfeiting, Mathieu Brichon. He runs the anti-counterfeiting laboratory and works on the development of new security features. He presented different types of counterfeiting and how to fight them; starting with very basic colour copies or scan-and-print reproductions made by opportunistic counterfeiters to extremely advanced and complex forgeries produced in high quantities by criminal organisations.

One case of high level counterfeiting was explained in more details. Some security elements were very close to the genuine ones, such as the watermarks, the security threads or even the UV luminescent inks. Some other aspects of the note had not been attacked; for example, the intaglio and tactile printing or the infrared mapping. These counterfeits were mostly printed in offset, so the reproduction of the micro-texts was accurate, but the rainbow effects, being simulated with two different printing plates, could have been more precisely registered.

Then the focus shifted to the equipment that is used to conduct the analysis of these reproductions and produce images for the reports. The installation of such a laboratory or the analyses of counterfeits are services that we gladly propose to our customers.KBA-NotaSys also conducts counterfeit deterrence researches. The first goal is to put our homemade security features to the test and assess their resistance to counterfeiting. The second objective is to keep in touch with the techniques used by counterfeiters in the field. This allows us to propose the best possible protection for your banknotes and to always be one step ahead of the forgers.

The KBA-NotaSys anti-counterfeiting laboratory plays a crucial role in accompanying clients and making sure their banknotes are secure. Do not hesitate to contact your Sales Representative for a demonstration of our techniques in our Lausanne Competence Centre or if you wish to train your teams.

GENUINE COUNTERFEIT


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WORKSHOP

EFFICIENT PRODUCTION: REDUCING WASTE AND RAISING PRODUCTIVITYPRESENTER: PETER HOPPER

At KBA-NotaSys we develop machines that help banknote factories produce more efficiently and effectively. We are also aware however, that while changing machines to the latest technology makes a huge difference, it is also important to look at the working practices in a factory to maximise the benefit from any investment.

The role of the Production Services Group is to assist banknote print works to obtain production benefits above and beyond the installation of equipment. The support we provide ranges from audits to assist factories improve productivity with their existing equipment, through a range of detailed training programs and small focused interventions, to offering long term production support.

We all expect technology to evolve so we need to be ready to adapt to new developments and optimise the way we work to fully benefit from the evolutions. Production Services Group provides a series of reviews and programmes that help you focus your efforts and resources to deliver the improvement you require. Thanks to an analysis of your current situation, we can work with you on:

• Quality Management Systems• Production Planning• Operational Performance Management• Preventative Maintenance• Machine health checks• Production reviews• Lean manufacturing programs (SMED)

As organisations go about their daily activities, it is often difficult to step back and review how they do things and more importantly why. We try to help organisations move away from “this is how we have always done it” and try to help them focus on what they want to achieve in the future. As Socrates said “The secret of change is to focus all your energy, not on fighting the old, but on building the new.”

Using this approach we have helped organisations achieve the following:

• Assisting a factory take its production from below €400 million to €1.1 billion in 3 years.

• Working hand in hand with a client to reduce its waste from 15% to under 8% (saving at the same time €2.1 million)

• Helped reducing job change-over times in an organisation on a Super Simultan from 28 hours to 10 hours, which improved productivity by 10%.

So if you are looking to buy new equipment, asses the equipment you have at present or simply want to look at maximising the performance of your current factory, we are here to help and let us help you make the difference and deliver Efficient Production.

TRAININGON SITE

TRAININGPROGRAMM

STANDARDOPERATING PROCEDURE

LONG TERMPRODUCTION

SUPPORTAUDITS

Pre machine order Pre installation Installation and comissioning Post acceptance


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WORKSHOP

ENHANCED CUSTOMER SERVICEPRESENTER: ROLF KELLER

Rolf Keller, Customer Services Group Manager, closed the two days of visits and workshops by presenting the new and enhanced Customer Services.

Being more focused on your needs means adapting the way we work. As presented in our recent Corporate Brochure that was distributed during Banknote Horizons 2016, we have developed a new approach allowing us to combine Modular Systems with Expert Services to offer you even more value. We call it Smart Solutions.

Smart Solutions always start with a clear understanding of your market and your needs. This insight allows us to define a specific combination of Modular Systems and Expert Services designed to offer even more value.

Expert Services are a comprehensive suite of newly developed services. They help maximise the full potential of our Modular Systems and also ensure our partnership continues to deliver long into the future.

Customer Services Technical Support has been enhanced to correspond to your feedback and make your life easier by:

• improving communication between you and KBA-NotaSys’ team of experts

• enhancing the efficiency of our responses• sharing our knowledge in solving your issues• reducing our response times• helping minimize your production downtimes

Bringing Customer Services to life in 4 steps

Customer Services cover interventions, check-ups, trainings, prepress services, preventative maintenance, end-of-life studies, quality, production support, partial and complete overhauls.

Additional aspects are under development like drastically improving our spare part service (offer and order lead time), developing Smart Solutions such as spare parts and maintenance contracts, business driven retrofit and upgrade packages, creating awareness and clear “End-of-Life” packages for electrical components and more. We plan to keep improving our services to make sure you benefit from our knowledge and expertise.

If you are interested and wish to learn more about our Customer Services, do not hesitate to contact us.

2Dedicated

team

3Optimised process

4One number

or email

1Ticketing

tool


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THANK YOU FOR ATTENDING BANKNOTE HORIZONS 2016, WE LOOK FORWARD TO WELCOMING YOU IN 2020!

ORGANISATION TEAM


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