Special Report: Binding
As printers try to squeeze every ounce of efficiency out of their shops, especially in this tough economic environment, one spot on their radar continues to be the bindery.
At the On Demand Expo this month, Standard introduced the Horizon BQ-270C perfect binder, featuring a color touchscreen that prompts the operator for key parameters, and an integrated digital caliper that measures and transfers thickness data—the most frequently changing book variable—to the binder. The fully-automated 270C can begin setting up for the next book while it completes binding the previous one, ensuring minimal time-loss due to set-up for short or even single-edition runs.
Standard also introduced new accessories for its Horizon BQ-470 four-clamp binder, which features interchangeable EVA/PUR adhesive tanks. Operators can use the SI-470 digital caliper to measure book thickness and automatically transfer this data to the binder for automated set-up. And the PM-470 Pre-melt tank provides longer runs between adhesive replenishment.
Demonstrating the Systems
Short-run perfect-bound books were produced on the On Demand Expo show floor at the C.P. Bourg booth. The Bourg BB3002 perfect binders in EVA and PUR configurations for economical production of short-run perfect-bound books were on display.
The Bourg BST10-d+ suction tower collator was connected to a new stitch/fold/trim bookletmaker capable of handling 14.5 x 23.5-inch output—the largest sheet size currently produced by digital printers. A new and highly automated sheet feeder was connected to a Bourg BDF document finisher and a Baum K20 knife folder, demonstrating high-efficiency finishing to reduce mailing costs. C.P. Bourg also featured Baum AutoSet and tabletop folders, and a Baum 26.5-inch cutter in its booth.
“Productivity is a key requirement in production finishing today,” said Richard Trapilo, executive vice president and general manager at C.P. Bourg. “All the products we [showed] at On Demand 2009 are high-quality, innovative and efficient tools designed to help users in traditional, digital and mixed production environments to turn print on paper into quality finished products faster and better.”
Digital Is the Name of the Game
Another bindery manufacturer integrating its equipment with digital presses is Rollem International. The firm recently premiered its Jetstream finishing inline with an HP Indigo 7000 digital press. Jetstream accepts a postcard sheet directly from the coating unit of the press. Its new auto-scan applies registration and accuracy to the printed image, followed by the auto-collation feature that gathers the finished cards into sets. The 10-up postcard sheet can be printed, coated, trimmed, cut, collated, and delivered in packs—all in one uninterrupted process.
The Jetstream can be configured to run in-line, off-line and near-line by rolling each section into the configuration the application requires. It is ideally suited for high-volume production, and has several back-end options including folding, plough folding, gluing, collating, die cutting and various types of packaging machines.
Bringing Binding In-House
In today’s competitive market, print shops are seeking any advantage they can find to be more efficient and keep revenue streams within their own firms. The bindery is typically one of the least efficient areas, and postpress manufacturers are responding.
“Printers are finding that if they install a piece of new equipment, like a die cutter, they can gain higher margin jobs,” said Heidelberg’s Maurer. “We like to call it the ‘wow’ factor in a marketing piece where a printer produces a stitched book in the shape of an apple. Something special that attracts attention.”
In response, Heidelberg introduced two new die-cutting and embossing machines. At drupa 2008, the Dymatrix 106 Pro was introduced. It features a link-up to Heidelberg Logistics, and delivers high-quality die-cutting with accurate register, operator-friendliness, and a stripping station that removes even the smallest pieces. And the new Varimatrix 105 is designed as an entry-level model to provide quality, flexibility, and cost-effectiveness with high productivity and minimum makeready times. It provides consistent precise sheet infeed and direct switch-over of side lays from pull to push mode.
To help printers with high volumes and frequent job changes, MBO America introduced the T535 EA (21-inch) buckle folder at last fall’s Graph Expo. The T 535 is ideal for processing short runs and multiple changeovers that demand frequent machine resetting. The folder is also equipped with a 15-inch color touchscreen with Vario-Control to simplify set-up with a clear visual operator guide.
