After FlexBook XL lines were installed at Elcograf, HP measured a 38% throughput increase on the presses themselves, with average run speeds of 960 ft/min — that quote comes from HP’s own sales manager, not from us. Command Companies achieved wage reductions across all three shifts and bought a fourth Magnum line within 12 months. Acutrack multiplied binder feeding throughput 5× while adding 100% block verification. Target cut in-store signage labor by 50% across 2,000 stores. Full details are on our case studies page. See our case studies here.

Three ways. Labor: zero-touch changeovers and automated handling move operators from lifting and feeding to monitoring — a full FlexBook XL line runs with two operators. Uptime: automated changeovers take active production from a typical 65% to 92%, which works out to 98.5 extra days of 24/7 production per year. Waste: format changes cost one book block of scrap instead of a make-ready burn, and intelligent waste management diverts transition material automatically. Every point of recovered press capacity converts directly into shippable revenue.

Because the press is the most expensive asset on your floor and it’s almost certainly waiting on finishing. A modern digital web press runs at 800–1,000 ft/min; conventional finishing typically sustains around half that, and every manual changeover stops the line entirely. That gap shows up as idle press capacity, overtime chasing output downstream, and make-ready waste on every job change — costs that compound every shift whether or not they appear on a report.

Every line is engineered around your press, formats, and throughput targets, so pricing is quoted per configuration. After a consultation and applications review we provide a budgetary quote for your specific line, with installation, tooling, and freight itemized. Book a discovery call and we’ll put real numbers against your production profile. Book a free personalized production plan here.

Magnum was founded in 2009 by Steven Fyfe, a veteran of offset printing and winner of The Queen’s Award for innovation. Today we have 150+ installations across 20+ countries, 117 experts across three continents, and headquarters in Barrie, Canada and Kettering, United Kingdom. We’ve partnered with HP since 2014, acquired Timsons in 2025, and acquired Kolbus digital finishing assets in 2026. Our machines are built around precision-forged, CNC-machined components manufactured in-house. Read more about Magnum Digital Solutions here.

Specialized Magnum technicians install every line, train your staff on-site, and back you with 24/7 remote support from both headquarters. Since 2020 our remote camera diagnostics have let us see and resolve issues on your line in real time, anywhere in the world — without waiting for someone to fly in. For in-person support, our facilities in Canada, the United States and the United Kingdom make it easy for us to send out a technician fast.

Most issues are resolved through remote diagnostics while your line keeps moving. And breakdowns are rare by design: Magnum machines are built to offset-press standards. As one customer running three shifts, five days a week puts it: “Downtime is not a concern with this custom Magnum equipment — it has the same build quality as an offset press.” When in-person technical support is needed, we will send over a skilled technician fast from one of our facilities in Canada, the United States or the United Kingdom.

It’s a five-step process designed around your production schedule: consultation, design (you receive 3D drawings of your solution), feedback, installation by our technicians, and training. Site-specific layout drawings are produced for every configuration before anything ships, and our systems drop into existing lines — inline with your press or offline roll-to-roll — with no press-line changes required. For scale: we adapted Target’s production lines and rolled out to 2,000 stores inside three months. Actual installation was completed in a matter of days.

Absolutely. Automation removes the positions that are hardest to staff — hand-feeding, lifting, and changeover labor. One barcode drives job recognition, format changeover, and verification with no operator intervention, and cells like the Flex Auto-Loader run unattended from a single button press. Your existing crew runs more output; Command Companies used that to achieve wage-reduction goals on all three shifts.

Custom engineering is how Magnum started, and it’s still how we work. For Target we developed an entirely new adhesive-based signage system, testing 30+ formulations with a PhD chemist. For Elcograf we co-developed the 2up glued book block system that became the FlexBook XL. Tell us the problem — we’ll engineer the line. Book a free personalized production plan here.

It starts with a conversation, not a purchase order: an applications and volumes review, then inline-vs-nearline configuration, site layout and install planning, and a budgetary quote. From contract signing you get 3D designs for review before the build, then installation and training.  

Magnum lines run behind every major continuous-feed inkjet web press. That includes the full HP PageWide family — T4250, T485, T490, T500M, and the Advantage 2200 — plus Koenig & Bauer RotaJET lines, Canon ProStream and ColorStream presses, Ricoh Pro VC-series presses, Kodak Prosper presses, and Timsons presses. Systems install inline with the press or nearline/offline roll-to-roll, so you can add finishing capacity without touching the press line. We’ve been HP’s digital finishing partner since 2014.

Integration runs in bothdirections from the finishing line. Upstream, Magnum lines run behind HPPageWide, Koenig & Bauer RotaJET, Canon ProStream and ColorStream, RicohPro VC-series, Kodak Prosper, and Timsons presses, with automatic splicers for non-stoproll changes. Downstream, the Flex Auto-Loader feeds the entrance conveyor ofany perfect binder — including Müller Martini (Vareo PRO, Alegro), Horizon(BQ-500, BQ-270V), Kolbus, CP Bourg, and Wohlenberg systems — and runs inlinewith Horizon inspection and cover-matching. The Rotary FlexFold delivers foldedsections directly into existing sewing and case lines and matches web-offsetfolder output. For end-of-line automation, lines integrate with automatedstacking and palletizing systems such as the Solema Pluton palletizer, and theFlexCart puts a collaborative robot at end-of-line — built aroundindustry-standard heavy-payload cobots such as the Universal Robots UR20/UR30and FANUC CRX series — loading three-shelf carts sized to the cobot’s envelope.FlexRetail conveys store-ready stacks to a downstream bander. Print-engine andline integration is engineered and proven by Magnum — if it’s on your floor, weinterface with it.

Yes — that’s the design requirement. The FlexBook XL and Rotary FlexFold run at 1,000 ft/min, giving 200 ft/min of headroom over a T4250 in performance mode; the FlexBook 22 and FlexCut match 800 ft/min 1:1. In production at Elcograf, average run speed across the line is 960 ft/min. The result is a zero throughput gap: the press never waits on finishing.

A 2D Datamatrix barcode printed on the web drives everything. The line reads it in real time and executes five steps with zero stops: job recognition, format changeover (cut length, signature, and trim auto-configure via servo re-registration), page-count verification of every block, glue activation, and finish quality inspection. Transition material is diverted automatically, and the line accelerates back to full speed with no tools and no operator — the cost of a format change is one book block of scrap.

Nothing stops. The automatic splicer executes non-stop roll changes with splice detection, and intelligent waste management diverts the splice and transition material away from finished product automatically.

Verification is built into the line, not bolted on after it. On FlexBook lines, every book block is page-count verified and finish-inspected before delivery, and split detection auto-rejects downstream. At the binder, the Flex Auto-Loader checks every block three ways — top and bottom barcode cameras plus a laser that measures actual thickness against the value encoded in the block’s own barcode. A mismatch of even a fraction of a millimeter is auto-ejected before it ever reaches your binder.

Web conditioning is integrated across the range: moisture control balances both sides of the web, silicone application kills static end to end, and the roller de-curler auto-adjusts as roll diameter changes. The Rotary FlexFold runs 18 lb bible-weight stock, the FlexCut runs up to 350 gsm with the heavy-stock option, and shear-slit cutting delivers clean edges.

Yes. Lines support JDF/JMF workflow integration, and the barcode-driven job recall system means job parameters travel with the printed web itself — the line always knows which job is running, without an operator keying anything in.

That’s the point of the design. Book blocks deliver perfect-bound and case-bound work; the Rotary FlexFold produces the same folded-section output as a web-offset folder — including folding with lip for thread-sewn work — so it drops into the bindery workflow you already run. The Auto-Loader feeds any binder, and lines integrate with automated stacking, feeding, and palletizing systems.

Less than you’d expect — the FlexBook 22 takes half the floor of comparable systems. Site-specific layout drawings are produced for every configuration, and service access is engineered in: the Auto-Loader rolls laterally on its own track so your binder stays accessible.

Customers running automated Magnum changeovers plan around 92% active production, with roughly 3% lost to job changeovers and 5% to maintenance — versus a typical 65/20/15 split on manually changed-over lines. Over a year of 24/7 operation, that difference is about 98.5 extra days of production.