Articles

Safety in the Bindery and Finishing Department

by: Frederick Hartwig

It’s often an overlooked fact, but many of the injuries and accidents that occur in the printing industry occur within the binding and finishing department. And as with any other production staff, bindery employees performing their daily tasks need to be aware of the risks and hazards when working with and around materials and equipment.

The main issues to address when approaching safety in the bindery are the same as with most other areas regarding safety compliance efforts. This includes performing a hazard assessment, reviewing equipment, establishing standard operating procedures, conducting employee training, and performing regular safety inspections.

Hazard Assessments

Performing a hazard assessment allows an employer to identify existing risks and/or hazards, prioritize corrective actions, and eliminate risks and/or hazards.

The basics of performing a hazard assessment involve conducting a full examination of work practices and production operations such as material handling, equipment operations, and personal protective equipment (PPE). From this examination, the necessary information will be gathered to break down the process to the point where risks and/or hazards can be isolated and identified. The final step in the process is the development of a system for understanding the possible consequences of the identified risks and/or hazards and establishing any corrective measures.

The important principles of an assessment include eliminating risks (and more importantly, addressing risks at the source), adapting work to the individual (if possible), and utilizing technology (when available/practical). Then it is important to implement measures plant-wide, including employee training and involvement. Finally, develop an assessment review schedule to ensure that continued safety is maintained.

Some of the more task-specific hazard assessment efforts involve investigating reported risks or hazards by employees, addressing “close-calls” which can quickly lead to an accident or injury, and introducing a safety review for all newly created jobs and/or jobs with any procedural or process changes.

Equipment Review

In any production environment where equipment is used, special attention will need to be provided on equipment operations. The three basic areas to address with regard to equipment are service and maintenance, minor service and maintenance, and guarding.

It is vital that all machines and pieces of equipment be maintained and serviced regularly. This activity will ensure not only that the equipment is operating efficiently, but that its safety features are intact and providing the highest level of protection for the employees. When performing any service and maintenance activities, the use of lockout/tagout procedures is required in order to prevent any unexpected activation or release of stored energy while an employee is working on the equipment.

Accidents as a result of not applying proper lockout/tagout procedures in the bindery and finishing department can have severe consequences. In one recent example, an operator working on a three-knife trimmer had his fingers severed when he was making adjustments and did not follow the proper lockout/tagout procedures. The operator shut off the machine, yet while he had his hands inside the unit clearing the jam, another employee accidentally engaged the equipment and caused the knives to motion, resulting in the amputation. Had the employee followed the proper lockout/tagout procedures, the injury would not have occurred.

The lockout/tagout standard requires the adoption and implementation of practices and procedures to shut down equipment, isolate it from its energy source(s), and prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed. It contains minimum performance requirements and definitive criteria for establishing an effective program for the control of hazardous energy.

There is an exception to the lockout/tagout standard, known as “minor servicing and maintenance”. In order for the exception to apply, the employer must ensure that the employee can effectively perform the minor service and maintenance task in a way that prevents exposure to a hazard, such as by the use of special tools and/or alternative procedures which keep the employee’s body out of the areas of potential contact with machine components or which otherwise maintain effective protection.

“Minor servicing and maintenance” is defined by OSHA as “those tasks involving operations which can be safely accomplished by employees and where extensive disassembly of equipment is not required” and the task must be considered routine, repetitive, and integral to the operation.

Under “minor servicing and maintenance”, lockout/tagout procedures are not required if the employer can demonstrate that the alternative protection measures enable the employee to perform the servicing and maintenance without being exposed to unexpected energization, activation of the equipment, or release of stored energy.

It needs to be understood that this exception does NOT exempt printers from establishing a lockout/tagout program. Printers still need to establish a compliance program for major servicing activities, e.g. electrical repairs, removing major components, etc. More information can be obtained on lockout/tagout requirements at www.gain.net.

While service and maintenance and minor service and maintenance are necessary for non-production activities, guarding is the rule for all production activities. Any machine part, function, or process which may cause injury must be safeguarded while the equipment is in the production mode. Such guarding includes fixed type, adjustable type, and interlocked.

It is important to note that OSHA does not allow the grandfathering of equipment with regard to guarding issues. So no matter the age or design of the equipment, proper guarding must be in place for production activities and must offer the required level of protection from obvious or potential hazards.

Standard Operating Procedures

The use of standard operating procedures (SOP) is an essential safety tool when specific details are needed beyond that of a general written program, or in cases where a formal written program is not required but for safety reasons a specific set of procedures is necessary in order to properly perform a task or job function. The most common SOPs for the bindery department are developed for material handling activities and specific equipment operation.

Material handling can involve moving materials either by mechanical means or by physical efforts. Both means should have SOP’s in order to reduce or eliminate any hazards or potential hazards. The SOP’s in this category would include instruction on such subjects as how to properly lift, load, and unload materials, and when and how to use mechanical means, as in forklifts and pallet trucks.

Specific equipment operations require specific sets of instructions. A great source for developing the instructions is the manufacturers’ operating handbook. Whether it is for a folder, a guillotine cutter, or forklift truck, using and/or incorporating the operation handbook as an instructional guide will assist in properly training the employee. Details should be provided so employees will understand under what conditions they are allowed to operate equipment, the intended design for the equipment, and any associated hazards while using the equipment. In some cases, a printer may find that a unique application or job requirement calls for a variation of the normal operating procedures. In such cases, a new hazard assessment needs to be performed and new operation procedures established that will allow for the operation while still providing an adequate level of employee protection.

In some situations, a written safety program can serve as an SOP, depending on how it is written. Written programs are the documents that help guide employees in the understanding and application of certain OSHA regulation requirements. They may outline how compliance will be achieved but may not provide the employee with enough equipment-specific or task-specific instruction. Most written safety programs are designed to reflect only the compliance aspect of an OSHA regulation and some formats lack the detail needed to use as an effective procedural guide. It’s also worth noting that not every production task has an associated written program requirement from OSHA, which makes SOP’s all that more important.

Employee Training

After the equipment is outfitted for safety devices and features, after the warning signs are in place, and once the policies and procedures are written, the key to safety on the job is put in place – the employee. Without a proper understanding of what is expected, how to perform tasks safely, how to use equipment safely, or how to recognize hazards, the human element will be a wild card for the employer.

Conducting safety training is the responsibility of the employer. Understanding and following the safety rules and procedures is the responsibility of both employer and employee. It is always in the best interest of the employer, as well as the employee, to see that safety training is conducted and periodically updated even beyond the requirements of OSHA. Understanding that mistakes do happen, in most cases accidents and injuries can be categorized as resulting from unsafe actions and/or unsafe conditions. Both of these situations can be avoided through proper safety training.

Employers must not only determine that their employees can technically perform their work assignments, but that they can perform them safely and in accordance with the requirements of company safety polices and OSHA regulations.

Safety training and work task procedures should go hand in hand. Being properly trained is to be trained in the best methods for completing the job tasks, while also maintaining the highest level of personal safety. The training curriculum should identify who should be trained (e.g. new and/or existing employees), the type of training that is required (e.g. initial, remedial, refresher), when the training should occur, and the frequency of the training.

Because it is not always possible for employers to monitor every aspect of an employee’s work day, it is crucial that the safety training provides enough understanding and information to allow the employee to sustain the necessary level of safety awareness and carry out work assignments in the safest manner.

Inspections

As a good rule of thumb for effective safety management, a general safety inspection should be incorporated as part of a regular business review and should be conducted every six months, but not less than annually.

These inspections must periodically be made in order to ensure that the rules and policies are still accurate, being enforced, and that all necessary control measures, if any, are being implemented. Inspections also serve to demonstrate the company’s commitment to safety.

Regular inspections should cover a check of the equipment to verify safety devices such as interlocks and guarding, as well as the proper operation of the equipment itself. A review of the safety records should also take place, which would include the OSHA Injury and Illness 300 log, employee training records, written safety programs, and SOP’s. Some individual OSHA regulations, such as lockout/tagout, will actually mandate that procedures and authorized employees be evaluated at least annually. A list of such mandatory inspection and review events, as well as voluntary inspections, should be developed and scheduled.

A physical walk-through of the area during production with an eye to safety is a good way to observe work area conditions and employee activity live. Generally, the bindery is the last stop before a product is warehoused or shipped to a customer. This is where a vast amount of material can be stored, stacked, and moved about between several finishing stations before ultimately moved out. Depending on the materials being handled, there can be hand trucks and forklifts used, as well as scrap material that is cut or trimmed off finished product, all contributing to slipping, tripping, and crushing hazards.

Always observe your operation, be aware of your employee’s performance, investigate problems, listen to suggestions, and immediately address any needs for safety training.

Rick Hartwig is the Environmental Health and Safety Specialist at the Graphic Arts Technical Foundation. For more information regarding safety in the bindery and finishing department, or if you have other safety related questions, please call Rick Hartwig at (412) 259-1792 or e-mail [email protected].

Determining the Right Ring Mechanism for the Job

by: Alex Lintzenich, US Ring

There are many factors that come into play when determining the right ring mechanism to use for each job. It is important to know what the mechanism will be used for, as well as the look and style of the binder. In order to come up with the best selection, customers should first ask themselves the following questions:

What is the overall metal length?

The most commonly used length is an 11′ long metal. These metals are used for the standard sheet size for U.S. pages. However, there also are metals that come in both 8 ½’ and 9 ½’ sheet size for other applications. Internationally, the A-4 sheet size (11 ¾’) is the standard, but there is little call for that in the United States.

How many rings?

The three ring mechanism is the standard in most binders. There also are six ring memo metals, as well as two and four ring mechanisms. Once again, internationally, there are some differences, but both the three and four ring metals can be found.

What is the capacity?

It is important to know how much the customer will be loading onto the rings. Most suppliers should be able to assist in determining the correct ring size, based on number of pages and page weight. If the customer does not know the quantity to be placed on the rings, it is best to err on the side of extra capacity as in most cases, reducing the number of printed pages to be placed in the binder is usually not an option.

What type of ring style to use?

There are three main ring styles: Round, Straight D, and Angle D. Each has its own set of advantages and uses described below:

Round: This is the most commonly used ring style, as well as the most economical. This style is used in practically every application and also comes in a variety of options and usually is mounted on the spine of the book. Round rings are the most heavily stocked and easy to locate.
Straight D: This style has a larger holding capacity than that of a regular round ring. The Straight D also will reduce paper tear as the pages move across the rings. This metal is mounted on the back cover, which allows the user to print along the spine.
Angle D: This ring type has the most holding capacity of any of the three styles of rings. While the pages are in the metal, there also is a stair-step effect, allowing the user to see all the tabs at once. As with the Straight D, this metal is mounted on the back cover, allowing the user to print on the outside spine. The design of this ring metal ensures easy paper loading, as the metal is perpendicular with the spine when it is in the open position.

Each of these rings has its own set of benefits. Choosing a ring style is up to customer preference and the particular job for which the rings will be used. It also is important to remember that all three of these ring styles are available in the options highlighted below.

Light Duty vs. Heavy Duty

In most situations, this is a preference decision more than a functionality decision. However, there are situations where it is important to look at these two differences. Customer use is the best indicator of which of these ring metals to use. If the ring metal will be used by a student with the idea that they will purchase a new binder each semester, then light duty is the way to go. However, if the ring metal will be used by a contractor out in the field, then heavy duty is the best selection.

Do you need a locking function?

Many times customers look for a ring mechanism that has a locking function because they want to be sure that the information stored in the binder stays in the binder. As the size of the ring is increased, a locking function becomes more helpful because the weight on the rings sometimes causes the ring metal to open on its own. A locking function helps prevent this from occurring.

What type of finish on the ring?

Most mechanisms come in a nickel or chrome finish, but black and brass metals have their own applications. Again, this is usually a preference decision but something that definitely adds style and elegance to the finished binder. What type of book are you producing?
It is important to identify what type of binder will be attached to the mechanism and how it will be attached. There are now different options, from a standard eyeleted metal to a Securemore (prong) metal that allows the mechanism to attach to the binder without the need for a rivet. Many people prefer this feature as it allows the customer to print on the spine, producing an eye-appealing, attractive binder as well as creating cost-saving efficiencies for the binder manufacturer.

Are new ring metals being developed?

US Ring has developed a new ring metal, “Insta-Clik”, which can instantly be opened with a touch of a finger. Insta-Clik is a single triggered, easier opening product that is an excellent option for young children, as it has an anti-pinch feature to it. Insta-Clik also is beneficial for customers with a physical disability who find that opening the traditional ring metal is difficult. This mechanism also can be used in an area where it is important for the customer to maintain a quiet atmosphere, such as a library or classroom. With these questions as your guide, you should be able to make a successful decision as to which ring mechanism to use for the particular job at hand.

US Ring is a U.S.-based manufacturer with headquarters in St. Louis, Mo. The company designs and engineers custom ring metals, dies, and metal stamping. US Ring also owns additional high-volume factories in China with US Ring direct oversight. The company has over 80 years of quality control engineering and long-term engineering managers with over 75 years of combined experience in the ring metal field. For more information, call (800) 888-8772 or visit www.usring.com.

Getting Involved in Your Community

by Dianna Brodine

Chances are, your business has been asked to donate to local charity events and activities. Chances are, your business has received a lot of those requests. Nonprofit organizations, by definition, have to run a very tight financial ship, and one way to cut budget costs is to solicit donations of cold, hard cash or in-kind services. With the decline of available grant money and the increased costs of doing business, it’s unlikely that the pile of requests from local nonprofit organizations will get smaller. But why should your business get involved?

Four years of my recent working life have been spent in development departments for nonprofit organizations. The majority of my time was given to writing letters, making phone calls, and visiting local businesses that could contribute financially or through in-kind services. During each contact, I stressed the ways our shared community would be improved. The business in question usually focused on the tax benefits. The challenge (although I did my best) was showing the business owner that it’s not just the local charity that benefits from a contribution.

It’s true. There are benefits for your business when you become involved in your community.

Take Advantage of Publicity

The most obvious benefit to your business is the free publicity that comes with making a donation. It’s marketing in its simplest, and least expensive, form. You want potential customers to know about your business. Potential customers are looking for your service. Publicity brings the two together. Yes, selling bindery services is more complicated than it is for the typical retail store looking for a $15 sale but your business won’t thrive if the people who need your services don’t know you exist.

The donations you make should have specific and well-articulated benefits associated with your contribution. Ask the group who is proposing the donation what publicity will be included. Questions you should ask include the following:

Will your logo be placed prominently at the event (for example: on posters or T-shirts) or on other visual publicity generated by the nonprofit?
Will your business be mentioned in the event press releases?
Will your organization be thanked in the nonprofit newsletter or on its web site? If you’re listed on the nonprofit web site, can a link be added to your business site?
During the event, is there a location that would be appropriate for displaying your business’ banner?
What hands-on opportunities are available for your business to participate in during the actual event? Don’t underestimate the value of your presence. Television and newspaper media often will be present at these events, as will potential customers.

Don’t be afraid to send out your own press release. Many times, information from well-respected businesses is received with more enthusiasm by the local press than that received from a charity organization.

Say Hello to New Customers

Media publicity is not the only benefit for your business. The networking opportunities can be priceless. Nonprofit organizations often have an extensive board of directors, made up of top management from local businesses. The majority of those businesses are generating annual reports, advertising booklets, product pamphlets, and other printed materials that are currently funneled through other binderies. Take advantage of the chance to shake some hands and talk about the special services your business offers.

Nonprofit organizations also receive contributions and support from individual donors. Those with the most influence have probably made significant donations in the past. Where did the money come from? Individual donors also can have connections in the community that will open doors for your business.

Don’t forget about possible business partner connections. Is there a printer in town that youd love to work with but haven’t been able to make a connection? Working together successfully on a project for a nonprofit organization is an easy way to sell your capabilities, efficiencies, and expertise to a potential partner.

There’s one other new customer to consider – the nonprofit organization. As a rule, nonprofits don’t like to spend money on items that could be donated. But you can bet that whenever my budget allowed, I spent the money I had with the local businesses that had given to my organization in the past.

Some of this may sound rather calculated. After all, isn’t giving to charity supposed to be about finding the most deserving organization? Not necessarily. It’s not unreasonable to make charitable contribution decisions based on which organizations have connections that could benefit your business. After all, it’s your dollar that is on the table. You have the right to decide where it will be most effectively spent.

Create Warm Fuzzy Feelings

So you’re starting to see some of the tangible benefits of community involvement. Your company logo could be on t-shirts all over town and you might find yourself shaking hands with future customers. But what about the intangibles? Yes, I’m talking about that warm, fuzzy feeling you get from doing something nice. As a business owner, you are in a position to affect positive change for the community in which you live. Adding your name to its roster of supporters could give a nonprofit just the lift it needs to make an event a success. The money or services you contribute could make a significant difference in the life of someone in your hometown. Sure, it sounds like a sales pitch, but I was often amazed by the number of people who didn’t understand that their donation, no matter how small, made a big difference when it was added to what others had given.

That warm, fuzzy feeling doesn’t stop with you. Your employees will feel it too. A project for a local charity is often a welcome break for employees who rarely feel a personal connection to the work they’re doing. And, although it may seem unlikely, your employees could be receiving some of the services provided by local nonprofits. Counseling services, local boys and girls clubs, programs for the elderly, and food banks are all run by nonprofit organizations. The community members that you are benefiting through your contributions could be the same people you work with every day.

Choose Wisely

With the variety of requests that come through the door each year, it’s obvious that your business cannot support every organization in town. So, how do you decide which requests are worthy of your attention?

The first step is to determine a budget for your business’ annual contributions. By setting aside funds specifically for that purpose, your ability to respond to donation requests is already predetermined and you won’t feel a strain because you’re using funds that were meant for equipment acquisitions or employee salary increases. When the budgeted funds are gone, your business is no longer able to accept requests (unless you choose otherwise).

Your business also should create guidelines for which types of organizations you will support and the value of the service you are willing to provide. Perhaps you feel strongly about supporting children or the elderly. Maybe you would prefer not to make cash donations but would be happy to work with a local printer to create program books or other printed and bound items. Your comfort level determines your involvement.

Finding out what other local businesses are contributing to a particular event could make it easier for you to decide if you will be participating. Are any of your competitors contributing to the same event? Do you want to avoid events that put your names together or do you want to emphasize your involvement as well? There’s no right answer to that question – it’s just one more thing to take into consideration.

Getting your employees involved also could be an effective solution. Ask your employees to make recommendations about which projects are a fit for your business. Form an employee committee to make the final decision. Or create an employee committee for evaluation purposes and get those donation requests off of your desk altogether!

Making a contribution to a nonprofit organization is a personal decision, but the next time your business receives an invitation to become involved in a community event, remember the good that you’ll do, not only for them but also for you.

Dealing with Static Electricity

by: Scott Shelton

Static electricity is often the cause of problems encountered in the bindery, hampering production and affecting product quality. By having a basic understanding of static electricity and by utilizing ionization equipment to control or eliminate the static charges, most common problems can be tackled.

What Causes Static Electricity?

Static electricity is an electrical charge on the surface of an insulative material such as film or paper. Static also can occur on a conductor, such as metal, if it is not grounded.

When two or more surfaces are in contact with each other, a transfer of electrons takes place between those surfaces. When the surfaces separate, the surface which has gained the electrons becomes negatively charged. The mating surface giving up the electrons becomes positive. The contact and separation is known as triboelectrification or tribocharging.

There are several factors that effect whether or not a material’s surface will support a static charge and to what degree.

Materials made of natural fibers, such as uncoated paper, typically exhibit high charges at high speeds in environments having low relative humidity. These materials tend to be very hygroscopic, having the ability to absorb moisture from the ambient air. As moisture collects on the surface of these materials, surface resistivity decreases which, in turn, increases its conductivity. This provides a conductive path along the surface for charges to flow to grounded metal rollers or any grounded metal surface in the machinery that the material may be in contact with, thus removing the charge from the print material.

Materials such as plastic films and paper with plastic coatings or high quality clay coatings tend to generate high charges even at slower machine speeds. Their high propensity for charging is due to the inherent high surface resistivity of materials with less tendency to absorb moisture. Some of these surfaces can support static charge potentials of tens of thousands of volts and maintain a charge for minutes, hours, or even several days. For that reason feeding, delivery, and stacking plastic or lightweight coated paper sheets can be a real challenge.

Some plastics may have been treated with an antistatic agent which can reduce the tendency to develop a charge. Plastic webs or sheets may be extruded with an antistat in the formulations. Many times papers are treated in the printing press with an application of fabric softener solution which acts as an antistat on the material. In either case, the antistat functions as a slip agent, reducing friction by attracting ambient moisture to the surface and increasing conductivity.

Other factors affecting charge generation are material speed, contact pressure, temperature, and type of surfaces in contact. Typically, high speeds result in higher static charges. Larger areas of surface contact and greater physical pressure prior to separation also result in higher charges.

Surfaces that are conductive or antistatic can be maintained in an electrically neutral condition by grounding. Materials such as plastics, resin coated and clay coated papers, and very dry uncoated papers are non-conductive. Grounding cannot eliminate static charges on their surface. Static charges on these materials can be controlled, however, by utilizing ionization equipment mounted in the process machinery.

Familiar to most machine operators, static bars are a common type of ionizer used for neutralizing sheets and webs. A typical static bar is electrically powered and is mounted in the production line an inch or two from the sheet or web material’s path. As the charged surface passes the static bar, it becomes neutralized. Placement of the ionizer is critical. It should be placed just ahead of the area in the process where static is causing the problem. It is recommended that a qualified static field specialist be consulted for proper ionizer selection and placement. This can save a lot of time and aggravation.

How Does an Ionizer Work?

Ionizers emit vast quantities of both negatively and positively charged gas molecules called air ions. The ions are made available to the charged surfaces where the electric field attracts the necessary ions of opposite polarity to its surface, thus balancing the charge on the web. The ionizer’s output is virtually unaffected by ambient temperature and relative humidity conditions and is compatible with most materials processed in the bindery.

A typical static bar has a range of about one to two inches. Some static bars are designed to operate up to several inches away from the target surface. Ionizing blowers consist of a fan blowing air over a series of ionizing emitters to extend the operating range even more, up to three to four feet. Ionizing nozzles and air knives use compressed air to provide a higher velocity of focused ionized air. A common application is to assist in sheet separation on pocket feeders.

Dealing with Static Problems During Production

Many of the problems relating to static electricity encountered in the bindery actually result from static charges generated in the print medium in the pressroom. As the web or sheet is transported through the various stages of the printing press, static charges accumulate on the surfaces. If static neutralizers are not used at the delivery of the press, a highly charged stack of printed materials is sent to the bindery. If the print media in a quality clay or resin coated material has large areas of ink coverage or is highly calendered, the static charges may be retained for several hours or even days if ambient conditions permit. The resulting problems encountered in the bindery are usually personnel shocks, jams in the press, or double-sheet pick-ups when trying to feed a subsequent operation such as a folder, collator, saddle stitcher, or perfect bound line.

The simple and most cost effective solution to these problems is to convince the pressroom to install a static neutralizing bar at the delivery of the press. Trying to deal with the problems of double-sheet pick-ups and jams at all the pocket feeders on a large side saddle stitcher or perfect binder can be complicated due to limited space and moving mechanisms at the pocket. A static-free stack of printed materials from the pressroom, however, doesnt solve all the bindery problems. For example, with a typical sheet folder, once the sheet leaves the feed pile, the tribocharging process starts all over again as the sheet contacts and separates from belt, rollers, and any other surfaces with which it comes into contact. Since tribocharging is a cumulative process, the charge on the sheet continues to rise to a level where the charged sheet is attracted to components of the machine and a jam or skewing of the sheet occurs. When making multiple folds, this can happen at several locations in the folder. A solution is to mount a static neutralizing bar over the paper path, just ahead of the point where the problem is occurring. Due to guides and rails which may interfere with placing a standard static bar an inch or two from the sheet, an extended range type static bar may be appropriate. For best results, the bar should be positioned where the sheet is floating with a little air space between it and the sheet machine bed. One ideal location, although not always possible, is to position the bar over the sheet at a transition point or break in the conveyor.

Folded materials obviously need to be delivered onto a stack. This is usually where the next problem is manifested. The folded pieces may repel each other, causing a mess at the delivery, or they may stick to each other, resulting in sloppy, uneven, impossible-to-jog stacks. In either case, two static bars properly placed at the delivery to neutralize both outer surfaces of the folded piece will render neat, trouble-free deliveries.

Personnel Shock

Uncomfortable electrical shocks to personnel in the bindery are not uncommon. When high static charges exist, especially in rolls or stacks of materials, the electric fields can induce a charge into nearby personnel. Since the human body is a conductor and usually insolated from ground due to rubber or synthetic soled shoes, a sizable charge can build up and will be stored in the body. When the charged person touches something conductive, such as a machine component or control panel, the discharge will be felt as an electrical shock. Using a static fieldmeter, or with the help of a qualified static control specialist, the cause of the electrical field can be located and the problem solved by neutralizing the source of the problem.

Shrink Wrap Packaging Problems

As a roll of film unwinds and passes through nip rolls, over idler rolls, turning bars, and the forming plows, static charges on the film can cause operator shock, press jams due to film clinging to itself or machine components, and breakage of the film. The attraction forces of the charged film may even lift non-adhesive labels off the item being wrapped. A couple of carefully placed static bars usually solve all these problems and result in trouble-free packaging operations.

Summary

Electrostatic charges develop on the print substrate during virtually all phases of printing and finishing. The resulting problems can slow production and affect the quality of the end product, both impacting the bottom line.

With the help of an experienced static control field representative and the proper placement of an appropriate static control device, static charges can be controlled in production machinery, enhancing product quality and increasing throughput in the finishing department.

Scott Shelton is the North American Sales Manager for SIMCO Industrial Static Control, an international manufacturer of static control products. During his 28 years at SIMCO, he has authored and coauthored several published technical articles and has presented technical sessions to the Society of Manufacturing Engineers, Society of Plastics Engineers, Screen Printing Association, U.S. Department of Energy, OSU Web Handling Research Center, Pressure Sensitive Tape Council, TAPPI, IML CON, and various electronics industry and industrial manufacturing groups.

The Benefits of Pick and Place Automation for Vinyl Binding Manufacturing

by: Ken Sherman

In the United States, PVC is by far the most commonly used cover material for loose leaf ring binders. The field of Information Storage also includes the use of CDs, DVDs and other digital media. Vinyl heat-sealed binders and cases have proven popular for these products as well.

Traditionally, vinyl has been the material of choice in custom binder applications since it easily lends itself to multiple color silkscreen printing, foil stamping, embossing or debossing, appliqué, and now even digital printing.

Expanding decorating possibilities even further, cover designs are now often printed on paper and then embedded under a clear vinyl overlay. Thus, virtually any artwork can be utilized within the framework of vinyl binder manufacture. This “entrapment” binder is somewhat similar to a retail “clear-view” binder where the user simply inserts the artwork into an open end of the clear vinyl overlay. Printing on paper is faster and much less costly than elaborately decorating vinyl.

The entrapment binder is better than a clear-view binder, because all sides of the overlay are sealed shut and the artwork can be placed very close to the seal on all sides. The seal also is much tighter to the copy so that air space is eliminated and the binder has a true “custom” appearance.

Entrapment binder covers, as well as other vinyl binders with many parts to assemble, become much more labor intense. Let’s get down to cases (pun intended).

Imagine a vinyl binder with interior front and back cover pockets, with three-pieces of cover art (front cover, spine, and rear covers) and a clear overlay. To assemble this cover, a heat seal turntable must be set up to provide for placement of TEN components:

Interior vinyl pocket
Opaque vinyl liner
Three chipboard pieces for front cover, spine, and rear cover
Opaque outside vinyl cover
Three pieces of printed cover artwork
Clear vinyl overlay

To run such a job, setup time is considerable because each station of the turntable must be configured for each of these parts. To run the job, a constant supply of these components must be furnished to the production line. To get reasonable production output requires two or three operators. Based on information from past BIA industry surveys, three operators can produce, at best, about 1,800 units per 7 1/2 hour shift, while two people can make about 1,400 or 1,500.

So we see that this type of binder is considerably more labor-intense than a standard vinyl binder cover that has only five or six components.

	3 PERSONS	2 PERSONS	(1 person automated)
OUTPUT	1,800	1,400	2,700
MAN HOURS	22.5	15	7.5
SETUP TIME	90 min.	90 min.	40 min.

Pick and place automation makes the most sense here. Production output can easily increase to 2,500 to 2,800 units per 7 1/2 hour shift, with only one operator needed. Let’s look at the impact this has on cost by comparing an automated production line with both a two-person and three-person non-automated production line.

The above table shows that an automated assembly line will produce 50 percent more units than a 3-person line with just 1/3 of the labor cost. Setup and changeover times are reduced by half. Note that this automated line can produce 93 percent more units than the two-person line with only half the labor cost. In both cases, setup and changeover time is reduced 56 percent.

Today, pick and place automation systems provide a cost-effective solution. Typical payback on this equipment is less than two years. The value of the labor savings is much greater than monthly lease/purchase payments, so cash flow is positive.

This same equipment also will run conventionally decorated binders with results that are superior to hand-placement of components. The secret is an optical sensor that locks in on part of the decorated design and can register on the design, rather than the perimeter of the material. The improvement in registration is astounding! This brings up another important element: ACCURACY. Pick and place machines can place a binder part to within 1/10,000ths of an inch accurately, every time. The improved quality of the final product can be easily seen. The dramatic reduction in spoilage is a further cost reduction.

Frequently Asked Questions

Q: Do I need to have a full-time “engineer” to operate and maintain the equipment?
A: No. The equipment, while sophisticated, can easily be maintained “in-house”. Most parts can be found at Grainger’s and other local industrial parts sources. Choose automation equipment from the most experienced developers. From the beginning, they will guide you through the process.

Q: The last time I checked, this kind of equipment takes up too much space and requires very large-diameter turntables. Is this still true?
A: Not at all. Use your existing turntables. Most plants already have 84″ to 96″ diameter turntables. All you add is one or two automation modules, depending on the kind of jobs you expect to run most of the time. A standard binder with 5 or 6 components requires only one module, while entrapment or clear-view binders use two.

Q: For clear-view or entrapment binders, must I buy two modules at the same time?
A: Your choice. The very fact that this equipment is MODULAR means you can add the second module at any time. The first module is generally a sheet and board feeder, so it can be used also for pre-sheeted decorated and undecorated binders. Until the second module is added, you can still make clear-view binders by using another operator to hand-feed the sheeted clear. You will still increase production speed, whether making decorated or clear-view binders, with the single module.

Q: I was under the impression that this equipment costs around $1,000,000 for each assembly line. We are just a medium-sized manufacturer and cannot justify that.
A: The kind of automation modules we are discussing here cost but a small fraction of that. As we’ve mentioned, the equipment will produce a positive cash flow and most likely pay for itself in less than two years.

Q: I had heard that automation is great, but only if you set it up once and run the same product “forever” because setup and change overs are so time and labor-consuming.
A: There are certainly machines on the market that fit that description but the modules we are describing can be set up and changed over in between one half hour and one hour. Far fewer fixtures are needed at each turntable station and that is what consumes time and labor when setting up or changing over. Programming each module is simple. A laser scanner “sees” the turntable setup and “learns” where each binder component must be placed. After that, repeatable accuracy produces consistent, quality covers every time.

Q: Can the modules roll-feed from pre-slit vinyl rolls?
A: Yes, modules can be built to feed either vinyl sheets or slit rolls. In the case of clear overlays, as in clear-view or entrapment binders, roll-feeding the clear is best. The module feeds the proper length of vinyl from the roll, cuts the sheet and then places it into position. Undecorated opaque vinyl also lends itself to roll-feeding. If you are slitting and sheeting your vinyl, such as for decorated covers, sheet feeding is ideal.

Q: What does the one operator do in a full entrapment job?
A: As we’ve said, a complete entrapment needs only one operator. This person removes the finished cover, then inspects and strips the “ribbon”. The operator then places (for example) the inside pocket and liner. The modules do the rest.

Q: Must the machine be stopped to load vinyl or board?
A: In the case of modules that are feeding sheet vinyl and board or entrapment-printed sheets, the machine can be loaded while continuously running due to double-width hoppers. If the module is built to roll-feed the vinyl, changing rolls would need a brief stop of 30 seconds to 60 seconds.

Q: What brands of automation modules are being used most in the United States?
A: This type of equipment was first developed specifically for our industry by Douglas Lee of Lee Manufacturing in Ste. Genevieve, Mo. There is more of their equipment in use in the U.S. than any other kind dealing specifically with the custom industry. Each module is designed and built-to-order. Automation is not a “one size fits all” affair. Each individual situation is looked at, analyzed, and the best automation solutions are then presented.

Ken Sherman is the president and CEO of Charles Leonard Western, Inc., the leading supplier of metals and devices in the Western United States. Sherman has been in the industry for over 40 years. He has been a frequent speaker/panelist at BIA Conventions and also has authored numerous articles for trade publications.

New Technologies in Cutting & Trimming

by: Dianna Brodine

A complex printed project begins with consultations between customer, printer and binder. The possibilities are discussed, printing and folding options are weighed, and a plan to reach the desired outcome is developed. Once the printed material reaches the bindery, an inaccurate or ragged cut can compromise days or even weeks of work and material. Since paper cutting is a repetitive process that can be automated with little to no operator assistance in most cases, new technology developments in the machinery used for cutting are catching the eye of bindery employees. A reduction in the number of times human hands intervene in a project can lead to a reduction in errors.

Before the First Cut

Before a machine can effectively cut the printed material, the material must first be loaded neatly into the machine. Colter & Peterson has recently installed its second BASA automatic jogging system from Baumann in the United States at a Florida commercial print shop. The BASA is the world’s first totally automatic jogging system that works without operator intervention. Skids of sheets are placed directly from the printing press into the system. They are then automatically counted and jogged. The air is squeezed out of the reams, which are then stored on racks or brought directly into the back of the paper cutter for cutting.

Automated Cutting Technology

Advances in automation can reduce the number of operators needed to finish a project, thereby reducing personnel expenses. To meet the automated cutting needs of binderies, Standard Finishing Systems offers the Standard Horizon HT-30, a three-side trimmer featuring automated job set-ups and quick changeovers to meet the requirements of the short run print-on-demand book market. The HT-30 operates off-line to trim perfect bound books at speeds up to 200 cycles per hour with the ability to store up to 40 different book jobs in memory. A touch screen operator console allows all set-ups to be performed with full automation. Precision stepper motors accurately position all guides and clamps to insure professional quality paper cutting. Up to 12″ of books can be loaded into the in-feed hopper, where books are automatically fed for unattended operation.

Heidelberg USA’s POLAR Automated Cutting for Efficiency System (PACE) is the industry’s first fully automated cutting system from POLAR. By automating the loading, jogging, buffering, cutting, gripping, transporting, and unloading processes, PACE produces high-quality finished products with the least amount of human intervention. PACE increases productivity, lowers costs, and reduces waste. As an added advantage, separate elements of PACE’s technology can be employed to streamline other production runs and requirements.

In addition, WinAmerica, Inc. has introduced the new Pro-Cut 360 36 and 450 45 models. Both models are mechanical knife driven and carry features like double linear back gauges, touch screen Microsoft programmable-based computers, main air table, air side tables, Mitsubishi servo drive, chrome table surface, and heavy duty cast frames.

Small Scale Solutions

There are automated solutions for jobs on a smaller scale, too. The Challenge Machinery Company’s new Spartan 185AEP is a fully programmable 18.5″ table-top paper cutter featuring electric powered knife drive, clamping, and back gauge control. Its software offers the table-top cutter industry its first menu driven controller, enabling the operator to simply navigate the programming sequence. During a program, the 3″ LCD control screen displays the next five cuts, allowing the operator to see where they are in a job at all times. Its memory of 20 programs / 20 cuts per program and exclusive maintenance-free feature makes the Spartan 185AEP a good value in the 18.5″ cutter market.

Rollem International has released the new JETSTREAM, a cutting and collation system ideal for finishing game cards, business cards, and playing cards on smaller formats. The two-directional slitting/perforating system is designed as an economical method for finishing multiple-up products when automated collation is not required. The model includes a manual collating table. Products are processed in one machine, eliminating labor expenses.

Focus on Safety

The Baumcut 31.5 programmable cutter offers high-productivity precision cutting with maximum safety in mind. Infrared safety beams, two-hand timed cut release, and covered rear table help ensure operator safety. The heavy-duty, fully hydraulic cutter features push-button programming and stores up to 99 programs with 6,464 cut steps. Programming is automatic. Simply cut the first ream manually and the cuts are then stored as a program. A large central LCD display indicates data in the selected language. Knife changes are easy, with a front adjustment. Built-in table light and optical cutting line indicator yields more precise cutting.

Unique Solutions

Folded materials scheduled for cutting can bring their own challenges. When planning to run a job two or three up on a folding machine, the folder operator is traditionally limited to slitting only lighter stocks with a limited number of folds. Typical complaints when slitting with conventional tools include ragged edges and crooked cuts. Technifold’s new Multi Tool eliminates these common cutting problems and delivers the capability to get guillotine quality trimming in-line on the folding machine. Using hardened counter knives with a special bevel design, it is now possible to slit or double-trim multiple panel jobs on heavy cover stocks (from 1/8″ trim up to 1 1/8″ trim). The Multi Tool also has a Micro Perforating component available and is made to fit popular MBO, Stahl, Horizon, G&K (Vijuk), and MB folding machines.

For soft cover projects, Zechini has introduced the Zinko, with a unique design that permits a precise trim on the face of gate folded perfect bound, saddle stitched, and sewn books. The Zinko is capable of running at speeds up to 3,000 books/hour in-line with a three knife trimmer or off line.

Start Off Sharp

Of course, for paper cutting machines to work effectively and create crisp, clean edges, the knife blades have to be sharp. GrindTech EdgeSM Technology from Jorson & Carlson is a proven sharpening process in the grinding of knives that has become an effective way of achieving optimum sharpness. The sharpening and honing process is the most important procedure in obtaining sharpness, less dust, better quality of cuts, longer up time, and less change outs. The GrindTech EdgeSM Technology incorporates a custom mechanical sharpening, deburring, and lap grinding process.

With new advances in cutting and trimming technology, binders can insure greater accuracy, reduce the number of operators needed to oversee a job, improve safety levels for their employees, and increase the speed of job throughput for customers. New technology creates a win/win situation for all those involved.

Planning for Internet Success

by Mary Napier

As potential customers turn to the Internet to research and make product purchase decisions, more companies are trying to market themselves and their products with the use of a web site. But you shouldn’t jump on the bandwagon without proper preparation. The web site needs to be well planned and executed, or the business risks spending money on a web site that doesn’t convey the message it wants or even worse, drives customers to the competition.

Developing a Web Site

Kathryn Fuller is a web site developer with Response Builders, a web site design company specializing in search engine marketing. Response Builders creates web sites that are comprehensive online marketing pieces, serving as useful tools for small to medium-sized businesses. According to Fuller, there are important elements to think about during the initial planning stages. Before beginning a web site project, each company should take time to clearly:

Identify their target audience who buys the company’s products and services and what would the target audience like to see on the web site
Outline short term and long term goals
Research other sites and determine what you like and don’t like
Establish a reasonable budget for the initial setup of the site and the updating of it
Set your priorities

Information Management Services LLC in Hillsboro, Ore. started a web site, www.mybinding.com, about three years ago. The company sells binding equipment and supplies, as well as filing systems and supplies. During the initial planning stages, IMS determined what elements it wanted on mybinding.com, set goals for the site, looked at competitors, and figured out ways to market the web site.

“We wanted to create a web site that was simple to navigate, but comprehensive to give our customers lots of choices, and we wanted it to look good and have a good feeling,” said Jeff McRitchie, business manager and the person who developed the site. “Our goal was to grow the business and continue to provide for ongoing growth.”

IMS developed the web site in-house and does all of the updating itself. This is something to consider when you are planning the budget for your project. If there isn’t someone on staff who is capable of developing the web site, your company should acquire several bids from professional web development firms. Then weigh the costs of setup and maintenance. Maintenance should be assessed since it affects the ongoing cost of the web site. “For successful e-commerce web sites, most companies play some sort of role in the maintenance of it,” said McRitchie. “I spend about 10-20 hours a week updating our site.”

Elements of a Successful Web Site

The next step is to determine what elements on the web site will be most successful in attracting and providing information for your audience.

The most important element, according to Fuller, is the content. “Content is king! Be sure content is clear, concise, and meaningful,” said Fuller. “Visitors to a web site are looking for information to satisfy a specific need. Determine the need and supply content that answers their questions.”

According to Fuller, companies shouldn’t forget to “sell” the web site they have created. When creating your site, don’t forget the following:

Strategically choose images and photography to enhance the marketing message. Be sure to keep download times reasonable for those customers with slower internet connections.
Optimize your chances with the search engines – a web site is only successful if potential customers know your site exists. Web site code should be written with the search engines in mind.
Keep your site fresh – update information on your site regularly to encourage visitors to return.

Specific content that could increase traffic to your web site includes reference tools, industry-appropriate articles, and elements that provide customer interaction. “Quality resources on a web site show that you are knowledgeable in your industry,” said Fuller. “As an added bonus, articles and tools of reference can help your site be found in search engines for specific keyword phrases.”

Customer interaction tools also keep your visitors interested and eager to return according to Fuller. Web site promotions, coupons, and referral discounts all give a customer a reason to keep checking your site. You can even demonstrate a product with a short video. “A lot of people think of a web site as an online brochure, but it should be so much more,” said Fuller. “A little interactivity on your web site can leave a great impression with your customers and prospective clients.”

McRitchie also had some advice for a successful web site, “Aim to be the best. There are so many choices, so know what you are trying to do and be the best at it.”

McRitchie suggests doing market research by simply looking at what other people in the business are already doing to see how you can accomplish the same thing. Then come up with a unique idea to market the same products in a new and interesting way. This will make you stand out among the competition.

Marketing Your Web Site

After a site is planned out and developed, marketing the site becomes extremely important. “No one will ever go to your site if they don’t know that it’s out there,” said Fuller. Fuller often uses online marketing strategies that include optimizing web sites for the search engines so the site gets a higher ranking under key word phrases. Building links to your site and paid search engine advertising are other elements to consider in an online marketing plan. Sending e-mails to clients and prospects also can inform them about what is new in your company.

When doing traditional printed materials or advertisements, it is very important to include your web address on everything. Companies also can mention the web address on phone messages, use direct mail, and write press releases. And don’t forget to talk about your web site to current and prospective customers.

Mybinding.com understands the value in marketing your web site. “Any good web site has to have a marketing plan in place,” said McRitchie. “A few things we do are to try to position ourselves positively on search engines, send out e-mails, and do direct mail pieces. We do anything to get our name out there.”

Plan for Success

Web sites can be effective tools to grow your business if they are developed and executed in the right way. If your company is looking to start a web site, be sure to go through the proper steps of planning, development, execution, and marketing. Then make a commitment to update the site and keep the content fresh.

“Planning is very important,” said McRitchie. “E-commerce is no different than any other business. You have to have a business plan to be successful.”

Fuller explains that a web site is only worth the investment if it does what you want it to do. “Just like any other piece of your business, if you’re going to have an online presence, you should devote the time and money necessary to do it right.”

Kathryn Fuller joined the Response Builders team in 2001 and opened the Houston branch of Response Builders in 2004. Fuller combines her web site design experience with up-to-the-minute search engine marketing strategies to provide her clients with a web site that is a true representation of their business. Fuller currently resides in southeast Texas and can be reached at (409) 386-0807 or [email protected].

Q&A: Radio Frequency Heat Sealing

by: Andy Oliner

Radio frequency (RF) heat sealing is the most common approach for sealing vinyl products – especially for loose leaf binders. This article will discuss some of the basic principles of RF heat sealing; why buffers are important in the process; and the most common applications.

Exactly what is heat sealing?

When you are fabricating an item from two or more pieces of plastic, you need a way of welding these pieces together. When you need to weld sheet materials together in an overlapping fashion, the preferred method is heat sealing. There are three types of heat sealing. In order of increasing cost, they are impulse sealing, RF sealing, and ultrasonic sealing. As the cost increases, the sealing process cycle time reduces. Most small and mid-size manufacturers have found RF sealing to be a good compromise between the cost in machinery and the benefit of increased efficiency and throughput.

What is RF heat sealing?

RF sealing works in much the same way as a microwave oven, where radio frequency energy is beamed throughout the interior of the oven. The frequency of the RF energy in a microwave oven is such that it excites the water molecules in the food that is in the oven. The water molecules start moving around a lot faster, which in turn, heats the food from the inside. Likewise, certain kinds of plastics have polar molecules. That means that they can be excited by RF energy, just as water molecules are excited by a microwave oven’s RF energy. An RF heat sealer is just like a microwave oven, except it is not enclosed and the RF energy is tuned to a different frequency – one that excites the plastic molecules instead of water molecules.

Heat sealing generally requires a solid, flat lower platen (on which the materials to be sealed are placed) and a heat sealing die above the lower platen. During the heat sealing process, the die comes down to the platen holding the material to be sealed and the die is energized with RF energy. This energy, along with the downward pressure that the head of the press is exerting, seals the material together in the desired shape.

Why use RF heat sealing to generate heat vs. applying heat energy direct?

Both methods accomplish the same end result, which is to get the plastic hot enough to weld together. The direct application of heat is referred to as “impulse sealing”. However, just as your microwave heats a lot faster than your regular oven, a RF heat sealer heats the material more quickly than an impulse sealer. Consequently, the rate of production increases significantly. In addition, plastic heated with RF energy cools down more quickly than plastic heated by conventional methods, which means it is safer to handle, comes off the machine more quickly, and keeps its shape better immediately after the sealing process.

Why is it important to use a buffer with RF heat sealing?

Another difference between sealing with conventional heat versus RF energy is that when using the RF method, a buffer is needed beneath the material to be sealed. Why? Believe it or not, the purpose of the buffer is to require you to use more RF energy to seal. As you seal, the plastic is melting and reducing in thickness, because the die is pressing down on nearly molten plastic. The RF energy is busy exciting the plastic, but like any electrical field, it is looking to complete the circuit in the easiest way possible. The nearest ground is the bottom platen of the sealing die. Without a buffer, as soon as the plastic is thin enough in one place, all the generated RF energy would flood through that one weak spot to the bottom platen and burn a hole in the product that is being sealed.

When you use a buffer, the additional dielectric resistance that the buffer provides means that even as the sealing area of your product thins, you continue to have a substantial electrical resistance to the RF energy. This keeps the RF energy diffused throughout the surface of the sealing die and stops it from breaking through one part of your product and concentrating in that spot. It increases the window between incomplete sealing (too little power) and burn-through (too much power). In addition, the buffer accomplishes the following:

Provides the right balance between sticking and releasing the material that is sealed.
Serves as a landing place for the sealing die that’s softer than the steel of the bottom platen.
Cushions the plastic being sealed to absorb inconsistencies in the material.

A balance between sticking and releasing is an important ingredient for successful RF heat sealing. The single most common buffer problem is sticking, with the plastic material adhering to the buffer and not coming away easily (special buffers are made to eliminate this problem). However, too much release also can be bad, especially if there is a multi-step sealing process. You do not want the product sliding all over the place as it moves from station to station. To achieve a good registration, the product needs to stay in place on the buffer belt. A certain amount of sticking also is helpful in that too much release can cause the product to stick to the sealing die instead of staying down on the buffer where it belongs.

What plastics and types of products are most commonly RF heat sealed?

The most common plastic utilized in RF heat sealing is PVC (vinyl), but other plastics also are being utilized, such as urethane, PETG, certain kinds of nylon and styrene, and polyolefins with EVA. The products that utilize RF heat sealing are more numerous than one might think. Some common products include the following:

Loose leaf binders
Packaging
Pocket protectors
Sheet protectors
Blow-up toys
Shower curtains
Intravenous bags
Seat cushions
Automobile tops, doors, and sun visors
Tarps, tents, and awnings

Andy Oliner is the President of Oliner Fibre. Oliner offers a large variety of materials specifically engineered as Heat Seal Buffers. For more information, contact Oliner at (800) 654-6373 or visit www.heatseal.com.

Perfect Binding Equipment Answers Need for Speed and Flexibility

by: Staff

With increasing pressure for faster production and turnaround times, as well as changes that on-demand printing has created in the graphics world, new equipment developments in perfect binding has changed as well. Manufacturers have rolled out machinery to perfect bind papers at a variety of speeds and in a variety of manufacturing environments, from desktop to the large high-speed equipment on the bindery floor.

BindIt has recently released the PERFECTBIND II desktop perfect binding machine. The PERFECTBIND II is designed to create professionally bound presentations and reports in small office settings. The PERFECTBIND II features a compact stream-lined design that binds up to 250 sheets. The machine contains auto shut-off, visual and audio indicators, a built-in cooling rack, and a selector button for normal or high capacity. Unique U-channel technology assures firm adhesion of all sheets.

Rosback Company has two perfect binders on the market, the 850 and the 882. The Rosback 850 perfect binder is ideal for the short-run, on-demand market. The 850’s heavy-duty single clamp adjusts in seconds for spines from 4 sheets up to 2′ thick. In-line notching produces the strongest binds by allowing adhesive to penetrate the spine. Notching can be turned off with one switch and pads can be produced with equal efficiency. The 850s precise cover nipper adjusts to the book thickness automatically to produce square, tight spines on books up to 15′ long. The Rosback 882 includes the best features of its predecessor, the 880 Book Binding unit, such as the unique ability to produce consistent, strong square spines, fast cycling speeds, and a hefty 2′ clamp capacity. The 882 adds a new operator interface that provides a central master control for quick setup and total system monitoring. The 882 includes cover joggers, a self-adjusting nipper, and an integrated book counter.

PRINT 05 in Chicago marked the world premier of the Standard Horizon BQ-470 fully automated four-clamp perfect binder from Standard Finishing Systems. The BQ-470 requires minimal operator training and produces up to 1,350 perfect bound books per hour, with four clamps that travel on a vertical elliptical track. The BQ-470 binder’s 10.4′ LCD touch-screen is used to provide servomotor-controlled automation to the professional-quality mid-range binding market. The BQ-470 can bind books up to 2.5′ thick and optional interchangeable glue tanks support both EVA and PUR adhesives to meet varying customer requirements.

The new generation of KOLBUS perfect binders offers the ideal solution for a variety of production requirements, including the binding of special products or large commercial runs. Economic efficiency, quality, and versatility are the distinctive features of KOLBUS perfect binders. Included in the KOLBUS line is the Perfect Binder KM 470, which runs at 6,000 cycles per hour and includes 21 or 27 clamps. This model includes fast format changes due to manual adjustment aids to meet practical requirements, as well as an optional gripper carriage delivery to carefully handle delicate products. The KM 473 has the capabilities of running at 8,000 cycles per hour and includes fully automated adjustments. It also includes touch screen, graphic operator guidance, and a remote diagnosis. The KOLBUS KM 411 is the high-production model that runs at 12,000 to 15,000 cycles per hour. It includes a fully automated format and block hang out adjustment. It has a central input and operating unit as well as touch-screens conveniently located around the machine for easy operation. All KOLBUS binders can be equipped with cold, hotmelt, or PUR glue pots. The KM 473 and KM 411 binders also include KOLBUS’s new spine processing technology. The 8, 12, and 15 thousand cycle per hour perfect binders are controlled by the Copilot System. The operator is guided through the operating procedure by an interactive dialogue.

New from Baum is the BaumBinder 1500 Perfect Binder, featuring a top-loading, bottom-feeding cover feeder and a two-part conveyor system for flexibility of finished book delivery. The BaumBinder 1500 offers efficiency and accuracy from clamping, spine preparation, and glue application, through delivery. A multi-tooth milling blade handles spine preparation and the thermostat-controlled glue tank features an application roller and back spinner. The BaumBinder 1500 operates at 1,500 cycles per hour.

Muller Martini perfect binding systems deliver advantages to bookbinding operations of all sizes. The company-s latest innovation is the 8,000 cycle per hour Model 3028 Bolero, introduced at PRINT 05. Bolero raises the production efficiency bar to a new notch, providing the highest levels of automation ever offered in a Muller Martini perfect binder, including the ability to perform its own makereadies. In addition, the Corona line is now available in three speeds – 12,000, 15,000, or 18,000 c/hr. The Corona C18 has a new generation touchscreen and is now more user-friendly. The CoronaCompact C12 is engineered for limited spaces. The Muller Martini family of perfect binding technologies also include the Acoro A7 (7,000 c/hr) and Acoro A5 (5,000 c/hr), each allowing timesaving on-the-fly adjustments of individual machine settings; the Tigra (3,500 c/hr), featuring menu-guided controls for easy operation and rapid makeready; and the AmigoPlus (1,500 c/hr) for short runs.

Perfect binding equipment continues to change and improve, driven by the needs of customers who want a professionally bound product in the fast-paced printing environment of today.

Vinyl Compatibility: What You Should Know and What You Can Do

by: Sheldon Cohen

Products that require two different vinyls to be welded to each other are at risk of distorting, usually in the form of wrinkles or bubbles. Understanding the causes of the distortion can be helpful in avoiding this problem. The three main factors that contribute to wrinkling are differences in plasticizers, differences in plasticizer levels and differences in rates of shrinkage.

I. Differences in plasticizers

What you should know
Although you might expect that “chemical” incompatibility be at the root of most wrinkling, it is, with today’s technology and vinyl manufacturing techniques, not the common cause for wrinkling. Chemical reactions usually manifest as random circular bubbles in the material.

The plasticizers commonly used in the calendaring of vinyl for heat sealing are liquids, usually with the viscosity of vegetable oils. They are added to powdered vinyl resins and are absorbed into the resin in a heating and mixing operation called compounding. The plasticizer molecules allow the resin molecules to “slide” against each other, which allows the vinyl film to be flexible.

There are many different types of plasticizers available that have been developed to provide specific end use properties. Most of the plasticizers that are used in vinyl calendering are from the phthalate group. The common ones are DOP (Di-n-octyl phthalate)*, DEHP, (Di (2-ethylhexyl) phthalate)*, andDINP, (Diisononyl phthalate). Note that DOP and DEHP are considered identical plasticizers.

Other plasticizers are from the adipate group. Adipates are usually used to impart better resistance to cold crack. A common one is DOA (Dioctyladipate).

Although the adipates are efficient plasticizers and perform very well in many applications, they have a different molecular structure than the phthalates, are more volatile, and have a greater tendency towards movement (migration).

What you can do
When welding two different vinyls together, check with your suppliers to be sure that the plasticizer systems that are used in each of their vinyls are compatible (i.e., from the same group). This is a routine caution and most suppliers will freely give such information.

Avoid using vinyl made from recycled scrap when welding two different materials. The formulations in the scrap can contain adipates and other incompatible ingredients.

II. Differences in plasticizer levels

What you should know
Differences in formulations are probably the most common cause for wrinkling. Wrinkling caused by differences in formulation can appear as a combination of irregular ripples and bubbles which are most seen near the corners of the welded product where the heat of the die has accelerated and exacerbated migration.

Every vinyl is formulated to perform in a specific end use application. The classic example is the end use differences in flexible opaque and clear vinyl. A producer of opaque vinyl for bookbinding would be primarily concerned with workability in the heat-sealing process, as well as some cold crack resistance, and would build his product accordingly. Since plasticizer acts to facilitate welding and helps to improve cold crack resistance, a typical opaque bookbinding formulation might contain 33-35 parts of plasticizer for every 100 parts of resin. Since the surface of the opaque product is usually embossed with a texture, the opaque producer is not concerned with the vinyl sticking together after sheeting.

The producer of double polished clear vinyl has different considerations. Since he will focus on transparency, his surfaces are as highly polished as glass. If he makes the vinyl too soft and flexible, it will stick together (block) when his customer sheets and stacks the vinyl. Therefore the clear producer will use very little plasticizer in his product (at the sacrifice of some welding and cold crack properties). Typical plasticizer volume in a “non-tack” clear vinyl formulation would be in the 24-25 parts of plasticizer per hundred of resin.

Here is a typical range of vinyl products from one manufacturer that shows their plasticizer content, going from soft to firm:

45 parts per hundred, 3-S
41 parts per hundred, 2-S
37 parts per hundred, 1-S (some medium bookbinding films)
33 parts per hundred, 1-H (most medium firm bookbinding films)
29 parts per hundred, 2-H (some clear non-tack overlay films)
25 parts per hundred, 3-H (most clear non-tack overlayfilms)

Even if the plasticizers in both materials are from the same chemical group, the plasticizer content of each material could be different. In a typical clear overlay binder, a material with 33 PHR plasticizer is placed in direct contact with a material with 25 PHR.

Because plasticizers are organic compounds, the materials, over time, will attempt to go into PHR balance. This means that plasticizer will attempt to leave the softer material and migrate into the firmer. When this happens, the firmer material (usually the clear) swells. Since the material is welded to the opaque and has nowhere to go, the displacement shows up as wrinkles in the clear. Another result is that as more plasticizer moves into the clear, the clear becomes softer than when initially produced.

Time is also a variable. Molecules of plasticized vinyl become more active as temperatures are elevated and will migrate faster. Another factor is how tightly the materials are pressed together. Heat, pressure, or any combination of both will accelerate migration.

What you can do
Specifying formulations that are closer together in PHR levels is one solution for very large custom runs but is impractical for everyday products. Be aware that decreasing the PHR in opaque will make the material more brittle and susceptible to cold cracking. Increasing the PHR in the clear vinyl will result in tackiness, which will make the clear vinyl difficult to handle for sheet fed work.

The best that the heat sealer can do when working with typical materials is to work to retard the transference of plasticizer:

Try to keep the thickness of the two materials as close as possible. A .006″ clear welded to a .014″ opaque will not absorb migrating plasticizers as well as a .008″ material and will show wrinkles more readily.
Wherever possible, slip sheet between the clear and opaque. This not only creates a barrier between the materials, the slip-sheet itself will absorb some of the plasticizer. Also, slip-sheets allow some air to circulate between the materials.
If the welded materials are stacked during or after manufacturing, keep the lifts as low as possible and never stack in lifts for long periods of time.
Ship products standing on end and mark the cartons: “This side up” and “Store away from heat.” Educate your customers accordingly.

III. Differences in shrinkage

What you should know
Both chemical and mechanical factors interplay to create shrinkage in vinyl. From a mechanical point of view, there must be some tension when winding up vinyl on rolls at the end of the calendar. A loosely wound roll would tend to telescope when moved. A tight wind helps to prevent the roll from flattening and reduces pressure marks during shipment and storage. Shrinkage caused by tension in wind up is called “snap back”. It usually occurs and is completed within a few hours after the vinyl is sheeted from the roll. A side effect of snap back is that as the vinyl shrinks in the calendaring direction, there is some slight increase in the width dimension. Attempts at introducing artificial shrinkage in low PHR vinyl by stretching at windup have not been successful.

A typical specification for mechanical shrinkage calls for not more than 1% change in dimension after 24 hours at room temperature.

After snap back is complete and as the vinyl ages, there will still be some residual shrinkage. Since flexible vinyl is a thermoplastic material, other stresses introduced in the manufacturing process will relax, causing the material to further condense over time. Another important consideration is the amount of plasticizer in the formulation. Softer vinyl tends to shrink more than firmer vinyl since their elasticity and elongation rates are higher. This brings us back to PHR of plasticizer differences in the formulations of two different vinyls that are being welded together. Normal bookbinding opaque vinyl with 33-35 PHR will tend to shrink more than a double polished clear vinyl with 25 PHR of plasticizer. Wrinkling occurs when two vinyls are welded together that have different rates of shrinkage. When one vinyl shrinks more than the other, the vinyl that shrinks less is displaced and this shows up as long undulating ridges of material. This wrinkling is exacerbated as the differences in the rates of shrinkage increase.

What you can do
Snap back can usually be handled in sheet fed work simply by giving the vinyl time to relax in low lifts after sheeting. Only a few hours is required to eliminate snap back problems. If roll feeding, dancer bars (accumulators) should be used to give the vinyl time to relax before reaching the welding die. Avoid introducing any tension in web feeding that could stretch the vinyl, especially when using softer materials.

With chemical shrinkage, since it is the nature of vinyl to shrink, heat sealers of two different materials should work with their suppliers to be sure that the vinyls that they are using have rates of shrinkage that are as close together as possible.

One highly respected bookbinder claims that he has minimized wrinkling by developing dies and heat-sealing techniques that weld the vinyl very tightly to the board and uses the board itself to staunch the vinyl from excessive shrinking.

As we have said before, when vinyl shrinks in the calendering direction, it can grow in the width. This sometimes causes a binder to look great coming off the heat sealer but “bag” a few days later. Vinyl sealed tight to the board will also minimize bagging.

Never cross grain materials when welding them together. Be sure that both pieces are taken from the roll in the same direction.

When packing heat-sealed products allow some space between the product and the top of the carton to absorb the weight of stacked cartons and not put pressure on the edges of the products.

Conclusion

Distortion (wrinkling), is an inherent problem when welding two dissimilar materials together. If the job is big enough to order specific vinyl formulations, the problem can probably be avoided at the outset if the heat sealer is willing to compromise some of the properties in each vinyl that makes them dissimilar. One can specify that the vinyl manufacturers use the same plasticizers and close the gap in the PHR proportions.

When this is not possible, the objective becomes to extend the amount of time that it takes for wrinkles to appear and to reduce the severity of the wrinkles by following some of the suggestions in this article.

The good news is that over the years, vinyl suppliers and their customers have made great strides in working together to create compatible products. The problems of incompatibility are much less frequent and much less severe today than they have been in the past.

Sheldon Cohen acts as Director of Marketing at Robeco, Inc. He can be contacted by calling (212) 986-6410.

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