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        2013 Fall

        The Secrets behind Award-Winning Projects

        November 15, 2013

        by Melissa DeDonder, The Binding Edge

        What does it take to create an award-winning piece? Four companies share production details, including secrets of success and challenges faced while producing their 2013 BIA Product of Excellence Award-winning pieces.

        McGraphics manufactures CMT Music Awards’ big reveal announcements

        CMT was looking for a “And the winner is…” printed piece that would complement the award show’s overall design concept. McGraphics, Inc. in Nashville, TN, worked with the designers at CMT and the print specialists at Buford Lewis to create the colorful, vibrant reveal cards.

        When the Country Music Television (CMT) network wanted a colorful, vibrant way to reveal the winners of the 2012 Music Awards, they knew just the company to call – McGraphics, Inc. in Nashville, TN. CMT was looking for a “And the winner is…” printed piece that would complement the award show’s overall design concept to the audience attending the show in person, as well as to the audience watching along at home.

        “The project was conceptualized by the CMT team,” said Fred Weisbrodt, lead salesperson, McGraphics. “It was brought to life and tested in a collaborative effort between the designers at CMT, the print specialists at Buford Lewis and the McGraphics team,” Weisbrodt said. The process included a diecutting dieline concept that was provided to McGraphics. First, McGraphics cut CAD samples to ensure the concept intricately glued together and slid open in a manner that worked for CMT’s production team. Then, CMT’s design team worked with Buford Lewis to ensure the metallic paper and interior color functioned properly and provided the look they desired.

        The foils were selected after completing a few color tests on sample stock. The exterior foils highlighted the award show’s bright and vibrant stage set designs. The pigment yellow and metallic red foils complimented each other well against the blue paper. The clear foil provided that extra “pop” to complete the look.

        The pieces were foil stamped on Brausse and Kluge presses and were diecut simultaneously on a Thompson press. The diecutting and all three foil passes had to be done together to ensure everything worked in unison with the tight registration. Then, interior metallic printed pieces were glue mounted together on the Potdevin to showcase the bright metallic on both sides. Finally, the pieces were hand assembled.

        Weisbrodt said the project’s biggest challenges included its time sensitivity, tight registration and sliding element. “The design team and print production team worked with us throughout the color selections and the CAD sampling process to ensure that we had our plan in place to produce the pieces in the limited time frame that we were given,” he explained.

        McGraphics met its challenging production goals head on, and the hard work paid off. “We’ve heard a lot of comments such as, “Wow! McGraphics did those?” and “That is so cool! I noticed them on the show,” as well as many others,” Weisbrodt said. “Ultimately, the finished product exceeded our expectations. When something is planned and tested so many times prior to production, the final product seems to exceed both your initial expectations and the client’s expectations, too.” The piece won a 2013 Product of Excellence Award in the They Said It Couldn’t Be Done category.

        Silvanus jet sets to new heights with a French Turned and Sewn binder

        The French Turned and Sewn binder by Silvanus Products, Inc. in Sainte Genevieve, MO, quickly became the company’s signature high end product.

        Many years ago, a customer asked Silvanus Products, Inc. in Sainte Genevieve, MO, to manufacture a binder that had a trademark. “Since we could not duplicate the binder, we made modifications to create our own design,” said Cathy Elliott, customer service and purchasing manager. Silvanus’ custom-created binder quickly became the company’s signature high end product. “People who want an upscale product love the French Turned and Sewn look, and we have been able to apply that same construction technique to many of the other products that we offer,” Elliott said.

        What makes the French Turned and Sewn binder stand out from a traditional binder is its construction and quality, especially on the inside of the binder. It has an additional board thickness that provides both sturdiness and aesthetic appeal, which creates a different look overall. “It’s all about the look,” Elliott said. From the manufacturing standpoint, the French Turned and Sewn product requires more labor and materials, and it is a more difficult job to produce overall. “You have to be 100 percent on top of your game – every step of the way – on the production floor,” Elliott said.

        For the Global Jet Sales Binder, Silvanus used a combination of heat sealing, sewing and foilstamping/debossing to register. Special care was taken during set-up and in quality checks to ensure the strictest production standards every step of the way. The biggest challenge for this project was that everything had to be precisely lined up – from the placement of the boards, the sealing and sewing to the assembly of the metals. “If even one detail would have been slightly off, it would have sabotaged the entire production,” Elliott said. The end result was a product that the aviation-based client was proud to showcase, according to a letter of gratitude that was sent to Silvanus.

        The Global Jet Sales Binder won a 2013 Product of Excellence Award in the Sewn Products category. In addition, the company won awards in the Applique category for its Curriculum Teachers Guide and in the Turned Edge Casebound category for its Frederick Binder.

        Holum & Sons reaps what it sows with M-Seed Training Kit with Binder

        The M-Seed Training Kit with Binder created by Holum and Sons Co., Inc. in Westmont, IL, includes a package to house a variety of training materials – a binder, wire-o book, CD/DVDs and a business card.

        If your client’s first idea doesn’t succeed… This was the case with the M-Seed Training Kit with Binder created by Holum and Sons Co., Inc. in Westmont, IL. The goal was to create a training kit to the customer’s specifications, and the concept included a package to house a variety of training materials – a binder, wire-o book, CD/DVDs and a business card – in a functional and attractive kit. Originally, the package was going to be constructed from corrugated material rather than a turned edge product, but the end user was dissatisfied with the original sample created.

        The designer’s initial concept included two large angled “pockets” with Velcro flaps to house the wire-o book and binder within the box. The team at Holum and Sons knew that a paper pocket would not offer enough stability to hold the weight of the book and binder, so the company’s challenge became how to construct the pockets to make them functional.

        Richard Holum, president, discovered the best solution was to create two separate angle boxes with a magnetic flap closure to form the top and bottom of the overall box. The angle boxes were constructed with a full back panel, and the lid and flap were built off of that panel. The CD/DVD and business card pockets originally were specified to be PSA-backed clear vinyl. To complement the clean lines of the design, the pockets also were turned into tipped-in paper pockets. “Since the lining of the boxes needed to precisely match the overall box lining and outer edges, we really needed to work closely with our customer, Fey Printing, to provide them with accurate templates for all of their printing,” Holum said.

        One of the greatest challenges for this project was its very small production window, especially for a product with so many components. “The project required a lot of cooperation from our client (the printer), our diemaker and our laminator,” Holum said. The multi-faceted challenges in production included the fit, form and registration of multiple parts. Each piece of the puzzle had to be sized and registered perfectly so that the end product came together as one solid package. Holum said there really were not any equipment issues to overcome. “Our team is accustomed to producing the unusual and supplementing our equipment with hands-on craftsmanship,” Holum said. “Sometimes the “old way” is the only way to achieve a high-quality, one-of-a-kind piece.”

        He said this project was one of the rare occasions where the company got the chance to meet the end user. “They were extremely happy with all aspects of the finished product, and they appreciated the group effort that it took to get the job completed on time,” Holum said.

        The M-Seed Training Kit with Binder won a 2013 Product of Excellence Award in the category of Special Products. In addition, Holum and Sons’ Diversified Real Estate Concepts piece won in the category of Product Design, and the Stranger and Stranger Card Box won in the category of Foil Stamping/Debossing.

        Binding Solutions nails it with innovative construction industry pitch book

        Binding Solutions, Inc. in St. Louis, MO, created a high-end product to help introduce L. Keeley Construction, peak interest and establish credibility with potential clients.

        When L. Keeley Construction needed a high-end product to introduce itself, peak interest and establish credibility with potential clients in the medium- to large-retail development sector, the company turned to Binding Solutions, Inc. in St. Louis, MO. The goal was to create a presentation that was clean in design and upscale in feel.

        The collaborative design process included Fred Taussig, COO, Binding Solutions; Ryan Dempsey from PQ Design Group; and the client, Charles Berg from L. Keeley Construction. The team chose a green fabric to match the “L. Keeley green” in the company’s corporate identity. Taussig said the frosted cover really helped pique interest in what was to come on the inside by featuring a panel that allowed for the exterior surface graphics to get their due respect, while hinting at the underlying cover page’s content.

        First, the acrylic cover panels were laser cut to form perfect edges and micro-radius round corners. The panels then were silkscreened. All of the gluing and turn-ins were done by hand. The spine and back panel consisted of 98pt binder board. The document was twin-loop wire bound and glued into the case via a 2″ cloth cover flap to hold the book in position.

        Binding Solutions learned a lot during production. “Acrylic is a fairly new material for us. After creating a few prototypes, we learned that the laser gives us very accurate dimensions every time. The edge finishing is nice and smooth, and we can radius the outside corners to whatever the design calls for – and they are perfect every time,” Taussig said. The company also evolved its gluing method for this project, joining the Cialux fabric to the acrylic panels for excellent registration and maximum adhesion.

        Taussig said that the learning curve paid off. “The entire presentation felt good, from the first impression made by the cover to the well-designed interior pages and the smooth page turning allowed by the wire binding,” Taussig said. The client was very pleased with the finished product and returned to order more shortly after the first order had been completed. The initial project now has grown into something more – a spin-off project with different colors and a logo for L. Keeley’s sister company, ADB Companies, Inc. The L. Keeley Construction Pitch Book won a 2013 Product of Excellence Award in the Innovative Use of Materials category.

        BIA Notebook

        November 15, 2013

        From the Chairman

        Mike Packard is the new director of the Binding Industries Association.

        Those of us in the binding, finishing and information packaging industry are challenged every day to know how best to manage and position our companies not just to survive, but to prosper. We work tirelessly to keep check on our expenses and, at the same time, we think strategically as to how we should invest in our businesses.

        The fact is there are many factors to analyze and many strategies to contemplate. Many times, these decisions fall under our sole care and control, leaving us to feel somewhat like The Lone Ranger.

        Fear not! All of the resources you could ever hope to have access to will be available for you at the 2014 BIA Annual Conference that will be held in Dallas from March 31 to April 2. With many, many suppliers at the conference, you will have an unprecedented opportunity to examine the latest materials, services and products all in one area, with qualified representatives available to answer all of your questions.

        If that’s not enough, you will experience unparalleled networking opportunities. The peer exchanges and the face-to-face networking exchanges only take place once a year… this is it!

        As 2013 draws to a close and as you start thinking about budgets and commitments for 2014, I certainly hope that the BIA conference will be your must-attend event and that all other commitments will take a second position to the conference. Consider the time you spend at the conference an integral part of your planning and an investment in your business. I am certain that the content and quality of the conference will exceed your expectations.

        Best regards,
        Chris Eckhart, Chairman
        BIA Board of Directors

        I Have Some Big Shoes to Fill!

        While meeting Binding Industries Association members and suppliers at PRINT 13 and speaking to people on the phone, I was glad to hear the consensus that Justin did an outstanding job as BIA Director. I promise to keep up that level of service and support to the BIA. I will ensure members get the resources they need from the association they trust, delivering both long-standing and new tools to help them grow their businesses.

        Let me share some of my experience with you. My background is in meeting management. I started my career working for Hilton Hotels Corporation and then moved into conference planning for the Association of Metallurgical Engineers. I came to Printing Industries of America in 2007 to manage sponsorships and the Premier Print Awards, which I have enjoyed for almost six years.

        Looking toward the future, I am up to the challenge of taking the BIA to the next level! We now are accepting registrations online for the 2014 BIA Annual Conference at www.printing.org/biaconference. And look for the new monthly enewsletter, Bound for Excellence, which will highlight the BIA Annual Conference, the Product of Excellence Awards, BIA news and much more!

        I am looking forward to meeting and getting to know everyone. It is an honor to serve this organization, and I know I will enjoy working with all of you.

        Mike Packard, BIA Director

        “Building Strong Bonds”

        This is the theme for the 2014 BIA Annual Conference, March 31–April 2, at the Fairmont Hotel in Dallas, TX. We have an outstanding program organized that focuses on practical information you can implement at your company. Sessions include topics on sales, workplace violence and marketing, as well as a unique leadership session presented by an ex-NFL player and director of player operations! For detailed information on the session and plant tours, please visit www.printing.org/biaconference.

        Management: Energize to Optimize

        November 15, 2013

        By Jack Daly

        We can’t expect different behavior than what we offer as an example. “We are the message” in our companies.

        Business leaders today must develop ways to thrive during times of constant change. Below are 10 specific actions designed to gain peak performances from our most important resource – our employees.

        Never before have we seen companies put so much pressure on their employees to work long and hard. John Hinrichs, president of the consulting firm Management Decision Systems, observes that “10 or 15 years ago, we used to talk about job enrichment. Now we talk about job engorgement.” Reasons for this stress-inducing tendency include the following:

        • Corporate restructurings that have wiped out layers of managers without reducing the amount of work they used to do
        • New technologies – which eventually will lessen the need for supervision – currently are causing tough transitions for managers and employees
        • Increased competition coming from both large, efficient players and niche opportunists

        Our challenge as leaders/mentors is two-fold. First, we must energize our associates so they can optimize their performance now. Secondly, we need to maintain balance and perspective in our own lives in order to have a proper working relationship with our associates.

        You are the message

        Communication is based more on action than on words. If we come in Monday morning out of sorts, walk straight to our office without saying “hello” to anyone and then shut the door – in what manner will our associates answer the phone that morning? We can’t expect different behavior than what we offer as an example. “We are the message” in our companies.

        Here are the 10 things to think about and then proactively implement. If you think some of these 10 “energizers” need to come from the top of your organization to be successful, we remind you that leaders start where they are. Do these on your own, and then see what happens around you.

        1. Energizers set direction for their units by writing quarterly mission statements. As part of this process, the team commits to established values. Enthusiasm is generated within departments as they formulate their shared missions. Revising those statements quarterly rekindles that energy and commitment, while also providing an opportunity for each person to develop appropriate short-term goals. Planning’s value is in the process, more than in the plan itself. Once your associates have “bought in” to your shared mission, you’re on your way to success!
        2. Energizers truly listen and thus are plugged in to reality. They are both open and inquisitive, and their search for ideas is never-ending and boundless. Useful suggestions come from competitors, suppliers, customers, front-line associates, trade groups and your own mentors. Don’t assume that listening is one of the things you do best. Our booked calendars, busy travel schedules and constant phone calls don’t help us become better listeners. And, as an opportune occasion for listening occurs, too often we are talking. So, ask yourself, “How much time did I spend truly listening?” Good listeners practice “zero-based thinking,” which requires that we forget the way we’ve always done things, and instead look at situations in new light. One way to judge how much we value input is to figure the amount of time we spend in our offices, sitting safely behind our own desks. But, energetic new ideas emanate from where things are happening. Most of us, thus, need to spend more time in the field. You can start this process by talking with your customers and then acting on their suggestions.
        3. Philosopher John Gardner refers to what he terms “tough-minded optimism.” Energizers possess such a spirit, which combines hope and realism as the driving forces in building a business. Again, focusing on customer needs helps make this happen. A leader is more interested in serving his customer than in worrying about what the board of directors will think. “If it’s meant to be, it’s up to me” is the rallying cry for energizers who, nevertheless, remain prudent and balanced They neither are foolish dreamers nor impassioned extremists. Instead, leaders are positive cheerleaders who each day provide a message of optimism for those with whom they work.
        4. Energizers forever are thinking about and articulating their company mission and values. At least once a year, give a speech reinforcing what you and the company stand for. Nearly every successful leader relates the concern of repeating the same message too often. Yet his or her supporting team usually feels they can’t hear such a message often enough. Providing an over-all mission statement helps each unit to construct its own specific mission. Studies have shown that 74 percent of employees rank information sharing as very important, whereas only half of all executives felt this was what their associates wanted.
        5. Where procedure manuals give rules, company stories offer morals. “Storytelling’s power is timeless,” says author Tom Peters. “The marketplace is demanding that we burn the policy manuals and knock off the incessant memo writing; there’s just no time. It also demands we empower everyone to constantly take initiatives. It turns out stories are a – if not, the – leadership answer to both issues.” Stories, which in a simple manner describe who we are and what we do, influence thinking and action more than procedure manuals do. Storytelling is one of the oldest forms of communication, and the energizer turns it into a powerhouse management tool that works in both large and small companies.
        6. Energizers are bureaucracy busters. “It’s no wonder we manage our way to economic decline,” says Stanley Davis. “Our managerial modes don’t suit today’s business. We still are using the model GM founder Alfred Sloan developed for organizing corporate America back in the Twenties. As a result, we have industrially modeled organizations running post-industrial businesses.” Energizers know the value of the motto, “If it’s not broke, break it.” They work outside normal rules, and thus stand out in the eyes of customers and their own associates. By unleashing your creativity, you can spark the energy within your organization. Even simple changes can mean a great deal to your unit or company.
        7. Great benefits can be found in delegating without abdicating. Remain accountable for your group, but don’t allow a decision to be made at a higher level in the organization than it needs to be. Your associates know the daily specifics of their jobs better than you do. Foster an environment in which they design their function in a framework consistent with the company mission and values.
        8. Energizers understand the Pygmalion Effect. People usually accomplish what they believe they are expected to do. If we have high expectations as leaders/mentors, our associates probably will show excellent productivity. Ambitious expectations are built by energizers who believe in their own abilities to train and motivate their associates. Simply being demanding is insufficient. Your associates actually will rise to the level of your trust or fall to the level of your mistrust.
        9. Energizing and leading people are more powerful than managing a process. By building trust with associates and customers, a leader/mentor puts together the team described in his or her mission statement. Effective leaders usually are appreciated for their interpersonal skills, rather than for their managerial abilities. People care more about what’s in a manager’s heart than about what is in his or her head.
        10. An energizer surrounds himself with associates who are positive and realistic, rather than negative. A “can-do” attitude characterizes the energized leader/mentor. It is seen in the unwillingness to take “no” or “it’s never been done before” for an answer.

        To make this possible, an energizer’s mission statement should include minimum production standards and continual training of staff. You also should spend most of your time assisting your best producers, rather than motivating and supervising marginal performers. Good recruiting practices are the basis of a productive office.

        In addition, consider hiring an administrator to handle your routine paperwork, so that most of your efforts can be given to increasing production.

        The characteristic of energizers who move organizations to their highest levels of performance is that of a dreamer. Fred Smith’s college term paper was graded “impractical” – but he used it as the basis for building Federal Express. Steven Jobs acted on his dream of having personal computers in every home and classroom.

        Energizers manage their dreams; and each of us has a like capacity with regard to our business. If we resist change, we will only fall further behind. If we merely go along with change, then we will just keep pace with it. But, if we create change, we will be the ones who lead it.

        Jack Daly brings 30-plus years of field-proven experience from a starting base with CPA firm Arthur Andersen to the CEO level of several national companies. Daly is a proven CEO/Entrepreneur, having built six companies into national firms, two of which he subsequently has sold to the Wall Street firms of Solomon Brothers and First Boston.

         

        Choosing a Mechanical Binding Method: Plastic Coil or Wire?

        November 15, 2013

        by Jen Clark, The Binding Edge
        Plastic coil comes in a variety of colors and often can be matched to a theme or to a company’s corporate identity.

        Mechanical binding can be a cost-effective way to create bound documents that open flat and can offer 360-degree rotation. With the right tools, companies can have professionally punched and bound documents produced in-house. Determining if a project needs to utilize plastic coil or wire, though, starts with knowing how the finished product should look.

        Since plastic coil comes in a variety of colors, it often can be matched to a theme or to a company’s corporate identity. Plastic also is more durable, said David Spiel, co-owner of Spiel Associates, Long Island City, NY, “although some feel that wire is more aesthetically pleasing.”

        Double loop wire is recommended when a straight registration of the open book is required.

        Plastic spiral binding, single strand wire binding and double loop wire binding all are mechanical types of binding, explained Anna Massey, sales and marketing manager with Gateway Bookbinding Systems Ltd., Winnipeg, MB, Canada. Single strand wire binding typically is done with an automatic process – the metal wire being formed and wound through the punch holes to complete the book. With double loop wire binding, the pre-punched book is “hooked” onto the open wire and then the wire is closed to contain the sheets. With plastic spiral binding, the pre-formed coil is wound through the punch holes and the ends crimped to complete the process.

        The popularity of one type of binding over another pertains more to the types of projects being bound, Massey said. “For example, calendars and desk calendars often still are done with double loop wire because when the item is opened, the double loop wire provides for even registration between the open sections,” she said. “Plastic spiral binding seems to have become the number one choice for student agenda books because of its safety and durability factors, as well as vast color selection.”

        In the US especially, plastic coil has become the binding method of choice, Spiel added. “There are many states that bar the use of wire in school books or books for children,” he said. “Designers in the US tend to get excited over the range of colors with plastic coil.”

        Added Massey: “Wire binding still often is viewed as the “strong” binding, because it is produced from metal. It’s an interesting perception because it is very easy to bend and distort wire binding – even just during transport. Plastic spiral is much more durable, but viewed – in some overseas markets – as the weaker of the two products.” Even though there has been a spike in the use of plastic coil in the European market, “double loop wire is much more popular elsewhere in the world,” Spiel said.

        All types of binding have their pros and cons, Massey said. “Metal spiral and double loop wire easily are distorted and bent when shrinkwrapped or packed. Plastic spiral is more durable and will bounce back and hold its shape if or when pressure is applied.” When a straight registration of the open book is required, double loop wire is the choice, she noted. “Plastic spiral will “drop” when opened – as the opened book’s left side follows the angle of the coil.”

        Spiel agreed, adding the left side’s “drop” is about one-half-of-a-hole lower. “That is the nature of spiral binding, but pages from left to right line up perfectly with a book bound with double loop wire. This is important with maps and ledgers,” he said.

        Metal and double loop wire have limited color choices available, while plastic spiral comes in over 50 different colors, Massey said. “Plastic spiral also is a smoother product, especially when in the hands of children. Metal and double loop wire have sharp edges that can snag,” she said. “From a production standpoint, metal spiral always has been viewed as a more automated process, but plastic spiral has seen a tremendous development in this regard. There are systems putting out 25 plastic spiral bound books a minute.”

        Companies that are producing documents in-house should consider outsourcing the job based on the size of the job and equipment capabilities. A project’s complexity and turnaround time also are important factors to consider. “If you only have manual equipment, you may only be able to bind 50-100 books per hour,” Spiel said. “A manual set-up will require two operators to achieve this output. If you have to pay two employees to do the work, it would be prudent to send large runs out.”

        Spiel and Massey agreed that binding thick documents sometimes can be challenging. “You can bind up to about 1?” thickness with double loop wire, using 1¼” diameter wire,” Spiel said. “With plastic coil, you can bind up to 2″ in diameter and about 1¾” in thickness.” He suggests using an automatic machine to bind thick books, “such as the Sterling Coilmaster that can bind up to 50mm in diameter,” he said.

        Gateway’s specialty is the PLASTIKOIL® plastic spiral, which is manufactured up to 2″ in diameter. “That can handle up to 460 sheets of a 20lb bond book,” Massey said, noting some manufacturers go even larger. Gateway also offers the PLASTIKOIL Binding Stick, which is a connecting device to join multiple plastic spiral bound books. “With the Binding Stick, there really are no limitations,” she said.

        When it comes to plastic spiral binding, there are a number of options available for pitch – the distance or spacing between the loops of coil. The key is to match the pitch of the coil to the punch pattern. If a document is punched with a 4:1 pattern, then it needs a 4:1 coil. Incompatibility between pitch and punch pattern can affect productivity. “With plastic spiral binding, a wider pitch of 3:1 or 2.5:1 always is recommended for coil diameters larger than about a 30mm,” Massey said. “That is a book thickness of 1″ or more. A larger oval hole in these wider pitches also is recommended. This wider pitch and larger punch hole provides the coil with more room to find its way and thus will improve productivity as much as 45 percent.”

        Double loop wire traditionally uses a 3:1 round or square hole for thinner books. A wider 2:1 pitch with a slightly larger round or square hole is used for thicker books. “Plastic spiral often was done with a 4:1 pitch round hole, but we’ve seen a shift over the past 10 years to a more logical .2475″ pitch 5x4mm oval hole,” Massey said. “The .2475″ pitch fits on the common 8.5×11″ and European A4 and A5 sheet sizes – without the need to pull punch pins and center.”

        Partially opening a thick book while driving the coil through the punched holes helps a lot, Massey said. “The coil is driving through only half the book’s thickness at a time,” Massey noted. Gateway also offers a “reverse cut” coil in the larger diameters to help aid the insertion process. “The reverse cut lead edge smoothly funnels its way through the punch hole in comparison to the standard cut lead edge – a great advantage especially when binding thicker books.”

        The Binding Edge would like to thank Anna Massey, sales and marketing manager at Gateway Bookbinding Systems Ltd., Winnipeg, MB, Canada, (www.plastikoil.com) and David Spiel, co-owner of Spiel Associates, Long Island City, NY, (www.spielassociates.com) for contributing to this article.

        Q&A: Paper Punching

        November 15, 2013

        The Binding Edge
        Binding experts believe on demand printing and spiral binding will continue to expand well into the future.

        Although technology has changed the manner in which information is received, it has not changed the need to archive important documents and reference materials. Binding experts believe on demand printing and spiral binding will continue to expand well into the future. The Binding Edge consulted with industry experts at Punchmaster Tool & Die Ltd. and Update Ltd. to learn more about paper punching technology in the digital age.

        What factors can affect the quality of the paper punch?

        Todd Boynton, owner of Update Ltd. in Chaska, MN, recommended investing in high-quality punching equipment and then maintaining that equipment to ensure that it holds up and stays sharp. “You have to stay on top of the maintenance and replacement aspect. The replaceable parts – the parts that do the piercing – are made in different capacities, and some punches are made better than others,” Boynton said.

        John Xynos, owner and operator of Punchmaster Tool & Die Ltd. in Sharon, Ontario, Canada, added, “Punching tools are highly misunderstood. For example, I commonly hear people ask for a spare set of punch pins. They figure that if they get a bad cut, then they simply can replace the pins and the hole quality will be as good as new. But, that is not the case,” Xynos said. He explained that when it comes to punching tools, it’s the fit that provides the hole quality. “If you have a bad fit – if the pin is sloppy in the hole – then the punch quality will be terrible. The sharp edge on the punch pins does help, but not as much as the proper fit does,” Xynos said.

        How can operators determine the best die to use for the punching job?

        Both Boynton and Xynos said die choice is customer driven. “There are many patterns available – oval, round, square, etc. – and there are six or seven different punch machines on the market that can create the pattern most desirable to the customer for the job at hand,” Boynton said.

        Have there been any recent advances or modifications to paper punching equipment?

        Xynos said that punching tools have not changed much in the last 10 years and added that if you don’t do it on press, you only can punch through so much thickness at a time – 12 sheets up to 4.5mm thick – regardless of new technology. Boynton added, “You can spend a lot of time and money designing conveyance or auto-feeding capabilities, but in the end, the job still will require a lot of handwork.”

        Xynos said that Punchmaster uses the best steel alloy for any application, and if new technology or materials become available, then the company will test it on a few tools. “We will build a tool using new materials and then provide it to a trade bindery for a trial period of time,” he explained.

        How has the demand for faster production speeds and smaller run sizes changed paper punching technology?

        Xynos said the switch to digital panels has resulted in faster changeovers for smaller runs. Boynton added that coil has sped things up nicely in the smaller-run market, but standard notebook work hasn’t changed much despite increasing demand for faster production speeds and smaller run sizes.

        What maintenance steps should be taken to keep the punch working efficiently?

        When it comes to lubrication, different tools require different lubrication. “All tools that have a felt strip should be lubricated only with oil,” Xynos said. “We recommend using only oil on all Punchmaster tools because our fit is very precise. The worst thing you could use on our tools is grease, which is too thick to get where it’s needed,” Xynos said.

        Boynton added that the cleaning, storage and handling of punching tools is very important. Once the teeth become dull, there’s an entire row of teeth that will need to be either sharpened or replaced.

        The Binding Edge would like to thank Punchmaster Tool & Die Ltd. and Update Ltd. for their assistance with this article. Punchmaster specializes in designing and building paper punching tools and providing equipment manufacturers with tool designs for use in their punching equipment. Update is a service company that provides a variety of equipment, parts and supplies for the finishing industry. For more information, visit www.punchmastertools.com and www.updateltd.com.

        2014 Product of Excellence Awards – Enter Now!

        November 15, 2013

        The BIA now is accepting entries for the 2014 Product of Excellence Awards.

        As you know, this competition honors “the best of the best” in binding, graphic finishing and custom loose leaf manufacturing. With 12 categories in the Graphic Finishing section and 17 categories in the Loose Leaf section, you should have no problem finding the appropriate category to enter your outstanding pieces from this past year.

        Winners are honored at the 2014 Binding Industries Association Conference. The entry deadline is Feb. 17, 2014, so don’t delay! Information on the categories and how to enter is available at www.printing.org/poeawards.

         

        Family Ties at Reindl Bindery Company

        November 15, 2013

        by Jen Clark, The Binding Edge
        David Reindl, right, and his brother Steven Reindl took the helm of the company in 2007. David Reindl is the company’s president, while Steven Reindl is the vice president.

        Being nice and treating people fairly is more than a business philosophy at Reindl Bindery Company. It is how owners David and Steven Reindl were raised and how they, in turn, are raising their own families. But as a business philosophy, the mantra has proven beneficial for both employee longevity and sales.

        The pair grew up at the full-service bindery, now located in Germantown, WI, which was started in 1978 when their grandfather and father went into business together. Over the years, Reindl Bindery has become a leader in the printing and publishing industries. The company is known for its award-winning quality, responsive service and innovative binding solutions.

        “The biggest reason we are successful is because of our ability to change and adapt to the needs of our customers,” David Reindl said, noting those needs have changed a lot over the years. “It also is important for us to treat our people as family. We take an interest in our employees’ lives. I think it’s important to recognize all that they do.”

        Father, son venture out on their own

        In 1978, Charles Reindl was ready for something new. The 43-year veteran at Boehm Bindery decided it was time to venture out on his own. Charles’ son, Dale, who was teaching printing at a Milwaukee high school at the time, also had been considering a career change. “My dad was at the point in his career that he was looking to do something different,” David said. “He had been teaching for many years. I think he had had enough of teaching at that point.” The father and son had worked together before at Boehm Bindery, and Dale had continued to work part-time at the facility when he was in high school and while on break from college. Creating their own bindery “was an idea (my dad) had always toyed with. It was just the perfect opportunity,” David explained.

        At first, Reindl Bindery took on small binding jobs and book repair for Bibles and text books. The company was located on the second floor of a building in Milwaukee, WI, and it grew as it purchased a few smaller pieces of used equipment to manufacture different types of books. In 1980, Reindl purchased the assets of Boehm Bindery and moved to a new location on North 3rd Street. Reindl then was able to produce casebound books, as well as perform other operations, making for a more versatile and complete trade bindery. In 1988, Reindl purchased a building in Elm Grove, WI, and moved for the second time. New developments within the industry allowed Reindl to be even more aggressive and after several machinery purchases, Reindl began competing nationwide and delving into new niche markets.

        In 1998, Reindl moved to Glendale, WI, to accommodate the growth of its bindery offerings and customer base. Another move in 2009 put Reindl Bindery in its current 112,000 sq. ft. facility. “At times, it isn’t enough space, but at others, it’s more than enough,” David said. “For a company our size, we are in a building that is the right size right now. We’re lucky though. If it comes to it, we have the ability to add floor space if needed.”

        Next generation takes over

        David Reynosa talks with David Reindl about a job in which the corners of covers need to be trimmed so the cover can be wrapped around board.

        In 2007, David and his brother, Steven, took over the company from their parents, Dale and Kathy. David is the company’s president, while Steven is the vice president and Dale remains chairman of the board. “They have no active ownership in the business,” David said of his parents, “but my dad is here when he wants to be here, and he’s not when he’s enjoying retirement. He’s sort of semi-retired. He takes part in production meetings and new product development. He kind of comes and goes,” David said with a laugh. “I think he’s enjoying it a lot.”

        The brothers, though, have had a role at Reindl Bindery from the beginning. “We all started when the company was founded in 1978 – I was nine years old,” David said. “We were brought in on Saturdays – I think to give my mom a break from dealing with three kids.” The boys’ jobs were far from glamorous and involved cleaning bathrooms and emptying trash cans while their father worked in the shop. This bindery is “what I’ve done since I was nine years old – in one aspect or another. We’ve both been here since the beginning,” David said. “It’s a strange feeling just switching ownership because we’ve been involved actively since the beginning,” he said. “We already were here doing the work – it was just a matter of making it official.”

        The brothers work well together, with their personalities balancing one another. “We don’t butt heads very often,” David explained. “I would say it’s a good system of checks and balances. He’s very calm and level-headed. I’m more aggressive. We balance each other out. We rarely have any kind of conflict, but (when we do) we’re tolerant of each other’s opinions. We bring different viewpoints to the table. We have the ability to look at things from different angles.”

        And, just as his father did, David brings his young children in on the weekends to get a feel for the family business. “At this point in their lives, they like to play office and go look around in the shop,” he said. But that doesn’t mean he’s pushing them into the bindery. “I would never push them to do it,” he said. “They have a long way to go before they need to make that kind of decision. I hope they would [join the business], but that’s going to be up to them.”

        Family atmosphere engages employees

        Scott Hill removes product from the Stahl folder at Reindl Bindery.

        Even though Reindl Bindery is hiring, most of the 55 current employees have been there for 10 years or more. “Some employees have more than 20 years with the company,” David said. “The longevity is remarkable.” He attributed the loyalty to the company’s family atmosphere. One way David accomplishes that is by saying “hello” to everyone each and every day that he is at the facility. He also lets employees know how important they are to the bindery’s success. “I make a point of being around when our employees meet to get their assignments. I want them to know how important they are,” he said, noting the employees appreciate the personal interaction.

        “We try to be polite and treat people nicely,” David explained. “They are our most important asset. Without them, we would be in trouble. I think it’s important to recognize what they do. Even though it’s their job and they get paid for it, I think thanking them at the end of the day for what they’ve done is important. And they appreciate that. We hold them accountable, but say thank you. It’s simple, really: Be pleasant and treat people nicely.”

        State-of-the-art technology – combined with a highly experienced work force – allows Reindl Bindery to provide a solutions-based approach to meets its customers’ needs. The full service bindery serves three major markets, including education, entertainment and trade. Capabilities include cover making, casebinding, perfect binding, mechanical binding, cutting, folding, drilling, foil stamping, collating, tipping, tab cutting, round cornering, shrink wrapping and DVD/CD. Reindl mounts trays and pockets to house CDs and DVDs for several media venues such as education, music, movies, television shows and more. It also produces single or multiple panel covers for use in casebinding, wire-o and for other applications such as game boards. Cover materials, whether printed and laminated, cloth or coated, are wrapped around the board that best suits each job. Casebinding jobs can be bound in various ways, too – Smyth sewn, side sewn or adhesive bound.

        “Our goal is to solve our customers’ issues and make it simple to work with us,” David said. “We do this by hiring the best people we can and instilling our company’s philosophy in each of them.” While there is no formal training process for new employees, existing operators serve as mentors by showing them the ropes. “It’s not a formalized apprenticeship,” he explained. “We look for people with mechanical aptitude and then train them to the situation by pairing them with a current operator for a period of time.”

        The timelines for training new and existing operators vary, depending on the situation. When new equipment is installed, Reindl takes advantage of the training provided by the manufacturer, though not all training takes place in-house. “For example, when we put our newest perfect binder in, we sent all of our operators to Germany for training,” David said. “It’s such an important part of getting all that you can out of the equipment. You have to invest in your people. Sometimes it’s a lot harder because you’re under the gun with various projects, but you have to do it because it’s better for the long-term.”

        Finding success in a changing industry

        In the last decade, digital publishing and changes in how people consume information have been problematic for many in the binding industry. As shorter runs became the norm, though, Reindl Bindery didn’t make significant changes to its model. “We have gone about our business,” David said.

        Job orders, he said, vary between short- and long-runs. “We are seeing a haphazard work load,” David said. “We have some incredibly large orders mixed right in with small- and mid-range orders. We just ran a perfect bound job that was a quantity of 250. We also just finished a 400,000-piece hardcover job. There is no consistency, and you just never know what you’re going to get on any given day.” Taking those challenges in stride shows clients how flexible Reindl Bindery can be to work with. “Often, creative scheduling of overtime and additional shifts is the only way to make it all work,” he said.

        The addition of new equipment over the last few years, such as a high-speed casing-in line and a high-speed PUR perfect binder, has given Reindl Bindery the ability to price differently because makeready and run times are faster. “Ideally, you can invest in equipment that will allow you to remain competitive,” David said. “We make our sales on our ability to always make our deliveries and take care of our customers. That always is how we’ve done business.”

        Reindl Bindery offers clients creative solutions, on-the-mark estimating, best-in-class production, quality assurance and on-time delivery no matter a project’s size. It has found a niche within the entertainment industry with high-profile work that has a worldwide audience. The company produces items for the music and motion picture industries, as well as lower quantity items for local customers.

        “We work on titles that are known and that are popular in the US and across the world. We work on a lot of different products with national recognition that put us in a spot that a lot of companies aren’t in because the high-profile things we are doing are pretty remarkable,” said David.

        Reindl Bindery recently won a Product of Excellence Award from the Binding Industries Association for its work on a piece for the movie The Dark Knight Rises.

        Reindl Bindery recently won a Product of Excellence Award from the Binding Industries Association for its work on a piece for the movie The Dark Knight Rises. The award recognizes the use of glue for finishing other than binding, where the application is intrinsic to the purpose of the piece, David said. “For Dark Knight Rises, we used a lenticular application without waves and made it flush to the board. Because of the UV coating, we used PUR. We had to adjust the glue pattern and build a pressing roller to pull the piece through, so it would flatten without damaging the piece. The outcome was an award-winning product that people everywhere could buy.”

        Reindl Bindery also has won awards in various categories for its work on a “Friends” anniversary book that was part of a DVD collection for the hit television show; the Wausau West Yearbook; a collection of CDs titled “Paul Simon: Graceland 25th Anniversary Edition”; and a specialty hardcover book that accompanied the Bio Shock video game. The “Friends” project was an oblong book with coated stock that required making various adjustments to the machines. The Paul Simon and Bio Shock projects consisted of a lot of handwork, and the book featured tinted pages to give it a weathered feel. “For Paul Simon, the material needed to be cleaned and our machines had to be modified for the larger size of the piece. We used foam to form the inside pocket as a guide and to protect the piece during shipping so that it wouldn’t bend,” David explained.

        “What we put out there are things that challenge us a little bit,” he said of the competitions the company enters. “If we win something for that, then it’s all the better. Obviously, when you’re showing people your office, it’s nice to have awards all over the walls. It shows your work is at an award-winning level. It becomes a marketing tool for us.”

        “Winning, for us, is like a pat on the back,” he explained. “It’s verification that we’re doing the absolute best for our customers. We take the most pride in awards that highlight things that “couldn’t be done”. That’s where you really show your level of service to your customers.”

        Another hurdle for the binding industry is work that has been lost to foreign companies – ones that can produce materials that traditionally take longer, but can be completed at a cheaper rate. To combat that trend, Reindl Bindery has become more aggressive in its marketing and customer contact. “I’m personally out on the road,” David said. “We don’t have an outside sales force. I’m the one going out and meeting with customers.”

        The approach is paying off because Reindl Bindery is growing its customer base. “Our marketing mostly is customer contact and website updates. We don’t send out mailers, but we do send out our company calendar each year,” he said, adding the distribution list gets larger and larger every year. “We’ve added multiple customers each month, a remarkable achievement, over the last eight to nine months. I’m using my time to get out there in front of customers and potential customers. I’m on the road several times each year, visiting places like Los Angeles and New York, as well as the central part of the country and locally – northern Illinois and Wisconsin.”

        David attributes the company’s success to its ability to change and adapt to the needs of its customers. “And they’ve changed a lot over the years,” he said. “If you looked at our company five years ago, we have evolved so much. We look different, but we still do the things we’ve done from the beginning. We’ll never forget where we came from, but we have to be forward-thinking and looking at ways to compete against not only competitors in our country, but competitors in countries like Mexico and China.”

        Innovation and creativity are the keys to retaining business that otherwise might go to foreign competitors, he said. “That’s where a big portion of our work will come from. I’m proud to say that is some of the stuff we’re starting to achieve. Being able to compete against Mexico is a big deal.”

        Simplicity plays a role as well. “We try to make our customers’ lives as simple as we can,” David said. “It is the key to our success. It doesn’t make our lives simple – it’s exactly the opposite. But by making our customers feel like coming to us is simple, that is how we win.”

        Increase Stacking Capability without Compromise

        November 15, 2013

        by Ken Troemel and Kevin Coldren, Simco-Ion
        Two charging bars installed on opposing sides of an incline stacker

        For years, electrostatic pinning (or tacking) has been an important tool for the printer and an integral part of efficient bindery operation. Effective and consistent pinning reduces run times and labor costs. Until now, the tools and strategies employed for electrostatic pinning have remained largely unchanged while the operations around them change continuously. Now, by remotely managing and monitoring output current and choosing, locating and maintaining the correct electrostatic charge bar, pinning systems can keep up with the changes to deliver consistent and cost-effective results.

        The theory of electrostatic pinning is quite simple – current is pushed through a charge bar and then the resulting high voltage is used to create a surface charge on various materials. This surface charge then acts as a temporary binding agent. In real world printing applications, however, it is not so simple. Many interrelated factors will affect the charging application. This article provides an overview of the charging process as it relates to the bindery, and it also identifies practices and products designed to increase the effectiveness of electrostatic pinning systems.

        Incline stack tacking challenges

        Despite the fact that the latest perfect binders and saddlestitchers can process up to 360 books per minute, it is not always easy to achieve that rated speed. Bottlenecks can occur in compensating stackers where publications are conveyed up the stacker, dropped into the compensator and stacked to varying heights. Magazine stacks must move quickly in order to keep up with upstream equipment.  When stacks are pushed out onto the conveyor or rollers leading to the packaging equipment, the mechanical forces that kept the stack straight no longer are present. As a result, the magazines and catalogs may shift, creating uneven bundles. The USPS can reject such bundles, forcing the bindery to separate and re-run the magazines offline.

        Making the process more of a challenge, perfect bound or saddlestitched publications with UV-coated covers have slippery surfaces that make them prone to shifting. High page count saddlestitched magazines also are difficult since the spine edge is thicker, causing books to slide toward the open edge and “shingle over” as they exit the compensator.

        Unfortunately, the entire line must slow down if the stacker does not produce neat, true stacks, and additional personnel may be required to manually straighten the stacks. While oval strappers can be used, the strapping material can damage the books and the post office may need to route individual magazines to their destinations.

        Use of electrostatics in the incline feeder

        Incline Stacking Tacking systems typically use a pair of charging bars, with one placed above and one placed below the publication’s path into the stacker. The bars normally are aligned with each other. Positive voltage is applied to one bar and negative voltage to the other bar using a high voltage bi-polar charging generator. The distance between the bars should be three inches for 30kV generators operating in voltage mode (see Figure 1 on previous page). However, this distance can be less at lower voltages or in current mode.

        When publications pass between the bars, the flow of negative and positive ions is interrupted, leaving the front and back covers oppositely charged. The bound product is compressed by the electrostatic force and when the charged book is dropped into the stacker, it lands with its back cover on top of the front cover of the previous magazine. Opposing charges on the magazines cause them to adhere together and keep the magazines from shifting before they enter the shrinkwrap tunnel.

        The result of static tacking can be quite dramatic. With certain books, production speeds on a typical finishing machine without incline tacking typically are only 175 to 200 per minute. When an electrostatic system is properly installed on the same machine, throughput can exceed 300 books per minute.

        Special bracket allows bar to pivot up for easy pin cleaning

        Maintenance of charging bars is an important component of any charging system. Dust or dirt around the emitter pins will reduce the effectiveness of a charging bar; therefore, periodic cleaning is recommended to prevent deposits from accumulating on the bar. A clean nylon brush with isopropyl alcohol applied is preferred. However, check with the manufacturer for specifics. Figure 2 (see page 26) shows a special bracket designed for use on the stacker application. The bracket allows access to Superbars installed on the stacker for easy cleaning and maintenance. It also provides a safe mounting structure to prevent operator shocks or voltage leakage and arcing conditions that can occur with conductive mounting materials.

        Selecting and using electrostatic systems in incline feeders

        Since there are many electrostatic systems available for incline tacking, it is important for a printer or binder to understand how the system functions and how to select the most efficient charging equipment.

        The most effective tacking is obtained when using charging generators that feature current control operation. With current control, the generator automatically adjusts the voltage to maintain a preset current. The system maintains stable and strong pinning power, lowering the output when there is open space between the magazines and extending the life of the charging bar. Charging generators with current control also adjust the voltage to compensate for changes in the line speeds, ambient conditions or paper dust buildup on the ionizing electrodes. Charging generators with current control operation eliminate the need for operators to constantly adjust the charging system to maintain the required pinning performance.

        However, not all current control power supplies are created equal. In addition to remote control and monitoring, it is important that the power supply has enough available current to handle whatever job is being run. Some jobs can be run with a minimal amount of current, while larger stacks or thick UV-coated books often will require more than 1mA of current. Selecting the correct power supply results in a more cost-effective and efficient bindery operation.

        Similarly, there are several choices available when it comes to electrostatic charging bars. Bar construction (the resistor, number of pins and pin material), sizing and placement are essential for successful pinning. In the bindery, bars with resistors are preferred. The resistor ensures that the bar operates steadily and reliably without arcing.

        While a tried and true technology, electrostatic tacking continues to evolve to meet the challenges imposed by today’s printer. Many electrostatic charging systems are designed for simplified integration into a printing or bindery line. Additionally, charging generators are becoming more compact in size, with features like low 24-volt input power. These newer advances are becoming a standard when selecting charging systems, as this provides for quick installation without the need to run high-voltage cables. Charging bars also are being fitted with tungsten emitter pins, which provide continuous performance and can significantly extend the life of the charging bar without the maintenance of replaceable pins. The latest innovations include a serviceable integrated static charging generator and bar in one system, which makes the system ideal for use in a variety of pinning and roll-to roll applications.

        Electrostatic charging can significantly enhance printing and bindery operations. Successful applications require a thorough understanding of charging technology and all the interrelated details, ranging from the charging equipment to the printing and bindery process itself.

        Ken Troemel is the western regional sales manager for Simco-Ion, Industrial Group. He has many years of combined experience in creating effective electrostatic solutions for various printing and bindery applications, with prior work experience with Tantec Inc. and MKS Ion Industrial. In 2010, Troemel joined Simco-Ion and transitioned into his current role where he is responsible for supporting all western sales representatives and distributors. Kevin Coldren is the eastern regional sales manager for Simco-Ion, Industrial Group. He joined Simco-Ion in 2000 and has over a decade of experience in solving static-related problems in various industries and applications. Coldren is responsible for supporting all eastern sales representatives and distributors. For more information, email CustomerService@Simco-Ion.com, call 800.203.3419 or visit www.Simco-Ion.com.



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