M = Modular for First in G&D's Next Generation Banknote Processing Systems

Giesecke & Devrient has recently introduced the BPS M7, the first in its next generation of banknote processing system. The last time the company undertook a complete redesign of its banknote processing systems was in 1996. Since then, there have been enormous advances in sensor technology, features and applications, many of which have been incorporated into the company's range as part of major upgrades which have typically been undertaken in 3-4 year cycles. However, Ralf Wintergerst, Group Senior Vice President and Head of the Banknote Processing Division, told Currency News that, given the pace of technological development, it was time for a complete overhaul.

Back to the Drawing Board
'Our business relies on innovation', he commented, 'and our objectives - based on feedback from our customers and our knowledge of the way the market is going - have been fourfold. First is productivity. Second is that the systems should be easy for operators to use. Third is that the sorting results are improved and are as close as possible to the perception of the operator / human eye. And fourth, the systems should accommodate different applications, such as multi-denominational sorting. On top of that, they need to be scaleable. In order to meet these objectives and take full advantage of new developments in sensor technology and software, we needed to go back to the drawing board.'

The BPS M7 is the first system off this drawing board. Based on the BPS 1000, a well-known processing system for central banks and commercial banks' cash centres and the leading model in the medium to high end market, it is a modular system that, says the company, is readily adaptable to customer requirements and, capable of sorting up 120,000 notes per hour, is setting new standards in terms of productivity.

New Sensor Systems
Core to the new machine, and a key innovation in itself, is the new Notascan 2 image sensor system for optical evaluation of authenticity and fitness. This comprises colour cameras with five times the resolution of their predecessors that allow full-face measurement on both sides of the notes in the red, green, blue and IR spectrum, along with transmission. As well as detecting the class of note (denomination, series, orientation and format), the sensors authenticate the notes' IR properties and watermarks, evaluates fitness (including of OVDs and ink wear as well as soiling, staining and holes, tears and missing parts) and detects and records serial numbers. Additional sensors can be incorporated to detect fluorescence, phosphorescence, the presence of optical brighteners, magnetic properties, electrical conductivity and G&D's own in-house high security features.

Another innovation is the DIS2 thickness sensor that recognises double and multiple items, the presence of tapes and tear and gauges the local grammage of banknotes, as well as authentication features such as micro-perforation, with evaluation of limpness as an optional feature. Furthermore, according to G&D, a dramatic step in resolution increase has been achieved, enabling additional two- dimensional analysis with unprecedented precision.

BPS M7 machines are fitted as standard with 12 sensor stations, 8 of which are double-sided (compared with the BPS 1000 which has 10, 4 of which are double-sided). A new feeding system with a capacity of up to 4,000 notes continuously feeds into the transport system, where a beltless section allows unobstructed full face measurement of the optical properties of the notes and their thickness. To keep optimum conditions for sensor performance, this section includes an integrated suction unit for removing dust.

Mixed Applications
A key requirement of banknote processing systems today is that they can sort not only mixed denominations but also mixed series, mixed currencies and mixed substrates (eg paper and polymer) presented in any orientation. The BPS M7 can accommodate such requirements with no changes in the input and sensor section, and has the option of multiple output stackers in combinations of two and four, up to a maximum of 20, each stacking notes in bundles of 100. The stackers all have an on-line dual supply bander with almost unlimited capability for printing of different characters in any language, while the use of two band reels that automatically switch from an empty to a full reel has increased the operating availability.

Additional options include an online shredder, a bundling and packing system that collates and shrink wraps five or ten bundles, and the integration of the Notapack module that conveys an unlimited number of different bundles of denominations and wraps, labels and packs them simultaneously. In addition to the stackers, a large delivery module with two independent output sections can hold up to 2,000 notes each. These can be used to collect notes for a second sorting run, or to stack loose banknotes in removable cartridges for filling cash dispensers.

Ease of Operation
According to G&D, the BPS M7 is up to 20% more productive than the BPS 1000 and a key development criterion has been its ease of use. Each system is driven by a series of touch screens with graphical user interfaces, the components can be easily cleaned (some, such as the sensor section, are self-cleaning) and covers and doors open and close automatically (including when faults are detected). User administration takes place centrally, single source architecture ensures that all systems behave identically and software updates only need to be uploaded at one location. The BPS M7 can also be connected to the customer's IT network to transfer electronic reports, which are based on Windows XP and Oracle platforms.

One of the main challenges of today's processing environment, said Wintergerst, is what he terms 'feature inflation', and the ability to update systems to read the plethora of new features that are continuously being introduced to banknotes. The company keeps abreast of such features by maintaining a database of the banknotes of more than 100 countries, containing detailed optical and other scans of every denomination and emission currently or recently in circulation. This is used to ensure that the sensor software is regularly updated to ensure optimum authenticity and fitness detection.

Demand Holds Up
Given the current economic climate, G&D was asked if now is the time to be making major investments when customer budgets are under severe pressure. The answer is yes, according to Wintergerst, noting that, even though the 'extraordinary' years of 2007 and 2008 are unlikely to be repeated, demand remains strong. 'Automation is all about productivity and efficiency', he said. 'These criteria become even more important at times like this so, in that sense, the downturn serves as a driver for the business'.

He sees the growth coming not just from replacement systems, but also from widening the installed base (which currently numbers 1,600 high speed systems), increased volumes and, above all, integration. 'The solution angle is key', he said, 'as is the ability to offer different options both for pre- and post-processing. Having a modular system relating to hardware, software and sensor technology, as we do with the BPS M7, is central to all of this.'

With the advent of a whole new generation of banknote processing systems, the company is also changing its naming convention, maintaining the BPS brand but classing each system into one of three categories - compact, medium and high speed. The new M7 fits into the middle category - the M stands for modular, as this is the defining characteristic of this and its sibling systems which will follow in time. The smaller desktop systems  - the Numeron and BPS 200 - will be prefixed C, standing for compact. At the top end, the high speed systems - the next generation BPS 2000 and 3000 - will have X, standing for extra speed.

Future Proof Investment
While the BPS M7 is a stand-alone new system, elements can be retrofitted to existing banknote processing systems. 'We need to be able to protect the current investments of our customers,' said Wintergerst, 'particularly those who have acquired processing systems in the past couple of years, the cost of which has not yet been written off. The versatility of the BPS product line means that the systems can be upgraded at any time to keep pace with changing business requirements, and it can also be integrated into M7 can be integrated into existing infrastructures and workflows. As such it is a future-proof investment.'

The BPS M7 is available now, while the regeneration of the whole range is likely to take 5-6 years.