2013 Winter

Special Report: Charting a Path for 2013–2014

February 1, 2013

by: Dr. Ronnie H. Davis and Ed Gleeson, Printing Industries of America

The following is an excerpt from a special report by Printing Industries of America. It was designed to help members assess the key trends impacting the economy and print markets over the next 12-24 months and to design strategies and tactics to take advantage of coming opportunities and address potential challenges. The report provides an environmental scan of recent economic and print market trends, plus the PIA outlook for 2013-2014.

Print Markets
The market space for printers has been changing dramatically for decades. While print-on-paper remains the keystone of the industry, “printers” are increasingly becoming “communications service providers” and moving into “integrated media.” This expansion of the print market space has created a new print plus business environment with expanded opportunities and challenges.

At the macro level, print’s economic footprint is massive, diverse and laden with opportunity for entrepreneurship, growth and profitability. At the same time, there are significant challenges from a very competitive environment – both among printers and between print and other media.

Our definition of the industry includes printing and related support activates (Economic Censes code 323), plus print-related media (Economic Census code 511). Print-related media includes newspapers, periodicals, books, directories/mailing lists and greeting cards and includes only activity directly related to print.

Print’s US economic footprint in 2011 totaled over $158 billion in annual shipments. The industry had almost 48,000 establishments employing just fewer than one million employees and hiring approximately 50,000 new employees per year.

The printing industry also is America’s most geographically dispersed manufacturing industry with a significant presence in all fifty states. Further, it is diverse in terms of size of firms with small, medium and large businesses represented.

Looking back at the last two years, Commercial Printing and Related Support Activities (NAICS 323) shipments have inched up just slightly (0.4 percent in 2011), while Print Related Media (NAICS 511) shipments have declined (4.9 percent in 2011). Establishments and employment have declined for both categories. Employment per establishment has increased for printing, declined for print media and remained stable for total print.

Throughout the course of 2012, print markets were boosted by hundreds of millions of dollars of direct mail promotion associated with the national election. However, print markets also were held back by the slow economy and the intense competition of digital media. Magazines and newspapers in particular are feeling the impact. For the first time ever, marketers spent more on digital advertising than print advertising in 2012. For example, Newsweek decided to become an all-digital publication.

New Year’s Revelations – The Economy and Print Markets in 2013-2014
Looking out over the next eight quarters (from the first quarter of 2013 through the fourth quarter of 2014), it looks like a pattern of 2.0-2.5 percent growth in inflation-adjusted economic gross domestic product will prevail. On the downside, we assume a continuation of only a minimum patchwork of cooperation between Congress and the President in addressing both short-run and longer-run tax, spending and deficit issues. On the bright side, the increasing energy production should keep energy prices in check and help with global competitiveness.

Of course, the elephant in the room is the out-of-control federal budget – especially mandatory entitlements like Medicare, Social Security and Medicaid and their negative effects on the economy and fiscal deficits in the long-run outlook.

Over the next two years, Printing Industries of America’s forecast calls for a continuation of the slow economic growth that we have experienced over the past year – around two percent adjusted for inflation. Commercial Print & Related Support Activities (NAICS 323), which we track and forecast on a nominal or non-inflation-adjusted basis, likely will remain stable in 2013 and grow slightly in 2014 as the economy improves. While the slow economic growth is not sufficient to pull print up by much, the good news is that the recovery has matured (although at a snail’s pace).

Print Related Media (NAICS 511) will continue to decline in 2013 and 2014, but less than the trend rate of 4.0 percent. In 2013 and 2014, we expect this sector of the industry to decline by about 2.0 percent each year. The reason for the slower decline is that we are in the “sweet spot” of the mature recovery for print. Although growth has been slow, this recovery has been consistent for the past two years and this is when it starts to positively affect industry shipments.

Overall for the next two years, as can be seen in the graph above, Commercial Print & Related Support Activities and Print Related Media shipments will decline by less than one percent in 2013 and remain relatively flat in 2014.

For 2013, print logistics (packaging and labels/wrappers) should lead the way and grow at a pace resembling the overall economy (two percent). Spending on marketing print (direct mail, catalogs and ancillary marketing materials) will suffer from the end of the election year and remain flat for the year. Expenditures on inform and communication print will likely fall around two percent.

Life Cycle and Competitive Position
Beyond the general business cycle are life cycle patterns in print. Over the past few decades, print has moved from a growth to mature to declining industry life cycle position overall, but there are differences by process and product. By process, digital toner and inkjet processes are in the growth phase. By print market segment and print function, ancillary services, packaging, labels and wrappers and direct marketing are mature but growing. A simple key indicator of life cycle position is the relative sales change by print sector compared to total printing shipments. Over the last decade, relative growth trends look like this:

In summary, printers should examine their segment life cycles and competitive intensity measures. In doing so, they should remain aware of these key points:

Print’s overall life cycle has moved from growth to mature to possibly a declining position.
However, a truer picture emerges when life cycles are examined by process, product and function. While some process, product and functions of print are mature or declining, many remain in the growth phase.
While all print sectors could be characterized as competitive, some sectors score significantly higher or lower in competitive intensity.
On both a life cycle and competitive intensity measure, there still is plenty of opportunity left in the printing industry.
Even in mature and declining sectors, there are management strategies and techniques for firms to improve their performance and do very well for a long period of time.

Dr. Ronnie H. Davis, vice president and chief economist, and Ed Gleeson, manager, economic and market research, serve in the Printing Industries of America Economic and Market Research Department. This excerpt presents a portion PIA’s annual review of the economy and print markets during the past year, plus PIA’s economic and print market outlook for the next twelve to twenty-four months. Additionally, an assessment of longer-term competitive issues for printers is offered. The objective of this report is to serve as a resource to plan the year ahead for your firm. To purchase the full report, contact PIA at 412.259.1770 or visit www.printing.org/store.

Dillon Bindery Stakes a Claim with Open Pot PUR

February 1, 2013

by Jen Clark, The Binding Edge

With run quantities getting smaller and more print communications going online, Dillon Bindery, Milwaukee, WI, had a decision to make. The family-owned business staked a claim by specializing in 2008; it became the first trade bindery in Wisconsin to offer high-speed, large-run PUR binding utilizing the open pot application. “The wide variety of paper and coating combinations are becoming more challenging and specialty jobs attempting to grab the reader’s attention are becoming more complex, which makes the use of PUR adhesive that much more important,” said Joshua Schroeckenthaler, vice president.

It wasn’t the first time that Dillon Bindery had diversified its offerings to meet its customers’ changing needs. Roy Schroeckenthaler purchased the small company in 1953, retained its name and operated it out of rented space on the third floor of its present location. As the business grew, so did Dillon Bindery’s reputation as a quality provider of binding and finishing services. Roy Schroeckenthaler purchased the building in 1964 and moved operations to the first floor. In 1978, the company began offering perfect binding, recognizing the need to diversify because of changing technology and greater demand for specialized service.

In 1997, Dillon Bindery expanded into mechanical binding. When Roy retired three years later, his son David Schroeckenthaler purchased the business. The company’s growth continued and in 2005, it added an automatic book drilling line. In 2008, it added a second perfect binding line. In 2010, Dillon Bindery added two more automatic book drilling lines and converted its other perfect binder to PUR, enabling the company to offer PUR on all perfect bound books.

Much of the company’s growth occurred in the midst of the worst recession since the Great Depression. According to Printing Industries of America, the Great Recession, which officially lasted from December 2007 to June 2009, shrunk print’s economic footprint by historic proportions. In 2008, the number of US printing plants declined to 33,565 and employment dropped to 909,200. The industry lost another 2,943 plants and more than 67,000 employees in 2009. Despite this, David Schroeckenthaler said, Dillon Bindery’s “growth was required to meet the needs and demands of our customers.”

Overcoming Obstacles with PUR

PUR adhesive is an alternative to other binding adhesives in the paperback book binding industry. It aids in overall performance and is a solution to ever increasing paper changes. “Printers are using more high-end products that require a lot of different coatings on the paper,” Joshua explained. “They are constantly changing the coatings and ink coverage. They’re also using heavier stocks. It was becoming a problem to get the book to perform the way the customer wanted it to.” Added David, “PUR overcomes a lot of those obstacles.”

In most cases, PUR is used to enhance the performance of page pulls and flexes to make a stronger book. A variety of factors, including proper spine preparation and residual print solvents, influence the ability of an adhesive to perform. Short fibers from recycled paper reduce the ability of an adhesive to bond to pages, while coated stocks, clay, aqueous coatings, varnishes and/or UV coatings can be difficult surfaces to bond. In addition, signature thickness and mixed paper stock can add stress to the glue line.

PUR-bound books have higher performance levels than similarly bound books using standard hot melt (EVA). The thin, tough and flexible nature of PUR enables the pages to open easily and have some lay-flat characteristics, “although PUR is not lay-flat binding,” David noted. PUR is resistant to a variety of inks and solvents, which can cause EVA hot melts to fail and leads to costly rebinds. In addition, PUR offers resistance to temperature extremes, which is beneficial during shipping and storage.

The combination of a poor adhesive with an inferior application method can be disastrous. Most binderies that offer PUR, Joshua explained, use the spray-on method because it is more economical. “They go with that because there is a waste factor,” he said. “Once PUR is exposed to air, it starts to set up or cure. So, they go with the spray-on system because it is more cost-effective as far as wasting the glue is concerned. Glue is expensive.”

Dillon Bindery utilizes the open pot application method, meaning technicians fill up the pot at the beginning of the day and drain it at the end of the day, repeating the process each day. “This process requires us to discard about $90 worth of glue between both binders each day,” Joshua estimated. “It becomes a cost factor for some people, but we’re not looking to save cost on the material. We’d rather put together a higher quality product instead of worrying about saving money on the material.”

Besides, the spray-on method has a higher spine failure rate, he added. “People view PUR as a magic glue, but it’s not just ‘a glue.’ It’s the application process. It’s how you prep the book and apply the glue. The spine preparation and the glue still is a big part of making sure you have a successful product at the end.”

The Schroeckenthalers agreed that PUR binding has become the company’s specialty. “Our customers can bind with a variety of stocks and coatings,” David said. “They aren’t limited to what they can use. They don’t have to worry about full ink coverage or the coverage of their coating.”

Dillon Bindery works closely with its glue supplier and tests various kinds of adhesives each year. The company uses leftover stock from previous projects to see what glue works best. “We don’t feel that all products are the same,” Joshua said. “There are a lot of people out there who use PUR, but they’re pretty price-conscious. They’re more driven by the price of the product, not how it performs.”

After thorough testing, deciding which adhesive to use is based on performance, not the company’s bottom line. “It can make a big difference at the end of the year on how much you spend on glue,” David said. “But if you have a job that needs to be reprinted because the glue failed, you’re responsible for that.”

Being educated with the advancement of adhesive technology and products is an important factor. BC Adhesives, Franklin, WI, helps Dillon Bindery in that regard. It specializes in the food processing and general purpose packaging, graphic arts and publishing, paper converting and product assembly and construction markets. BC Adhesives offers a hands-on relationship to its clients. It offers a strong portfolio of the leading adhesive brands, technical expertise and intimate knowledge of the complete range of customer production equipment and product substrates.

“They have an extensive knowledge of the book binding process,” Joshua said. “There are a lot of suppliers out there who sell glue, but they don’t know anything about how it is used or the process. They’ve never even seen the machine that they’re using it for. BC Adhesives puts in a lot of time and they have a lot of knowledge about the binding process. If there’s ever a problem, they are right there to help you out. They are staying on top of the new products that are coming from the different glue companies.” The results of the collaboration are clear. In the five years since Dillon Bindery started running PUR in the open pot application, they haven’t had any spine failures.

Custom Quoting Program Gives Competitive Edge

A computer-based, in-house quoting system that David developed about 12 years ago gives Dillon Bindery greater flexibility when quoting new jobs and analyzing completed jobs. It helps to track costs – start to finish – for each project. When he started building the system, there were other quoting systems on the market, but they were geared more toward printers with in-house binderies, Joshua explained. “Other programs lacked the detail and flexibility required to consider the many variables associated with the binding process,” David said.

Because the software was developed completely in-house, it allows Dillon Bindery to make changes on a regular basis. “Since we are constantly quoting, if there are things that need to be changed or tweaked, we can do it right away,” he said. “We are quoting every day. We see little things here or there. The way we have it set up, when we’re done with a job, we can analyze time sheets and cross reference that with the quoting data. It is very simple in how it is set up. It shows a lot of detail that we can use to analyze the time sheet afterwards.”

The software tracks factors like quantity, stock, material cost, labor cost, machine cost – “everything it takes to put a book together,” David said. It also shows comparisons on different ways of processing a job. “It can tell us which option is the most economical choice.”

A lot of the custom jobs Dillon Bindery works on have small- to medium-size run lengths. “The software will tell us exactly what our costs are for a particular project,” he said. “When we look at the time sheets, we can see exactly how much time was spent on a job as far as machine time, labor hours, etc., and we can go back to the quote to see exactly how the quote compares to the amount of time actually spent doing the job. It allows us to take all the costs of the material added into the final time sheets and gives us an exact analysis of how the job turned out compared to how we quoted it. We can see if adjustments need to be made in our quoting or not.”

The process has allowed Dillon Bindery to stay competitive, while keeping an eye on the bottom line. “Materials, including adhesive, are constantly changing in price,” Joshua said. “The software allows us to analyze that better. It gives us a better understanding of what it costs to do business.”

Humble Beginnings with an Eye on the Future

Dillon Bindery operates out of the same building it did when Karl Dillon founded the company in the 1930s. Its central location within the Milwaukee metropolitan area makes it convenient for local customers. Interstate access is also available for customers from as far away as Green Bay, Steven’s Point, Madison, Chicago and Indiana.

The company leans on its 70 years of book binding, magazine binding and catalog, calendar and brochure graphics arts finishing experience to produce high quality professionally bound publications to serves small, medium and large printers from its 25,000 sq. ft. facility. In addition to PUR and EVA perfect binding, it has a variety of mechanical wire binding, stitching (stapling) and folding capabilities for binding projects where a professionally bound look at a low price point is essential. Equipment at Dillon Bindery includes two Osako saddlestitchers, a Christensen Gang Stitcher, two Kolbus perfect binders, a 30-pocket Duplo booklet maker, five folders, three Durselen automatic drilling machines, two cutters, twin loop and plastic coil binders, along with miscellaneous equipment for eyeletting and elastic tag stringing.

Looking forward, the Schroeckenthalers see continued research and improvements in the PUR binding application and streamlined manufacturing in all processes. “We’ll continue to educate printers regarding the PUR process and the advantages it offers over conventional EVA perfect binding,” Joshua Schroeckenthaler said, noting the company may add inkjet capabilities in the future.

Keeping the business in the family has allowed the Schroeckenthalers to be very hands on with the operation. In addition to father, David, and son, Joshua, there are two other family members on staff. “We all started out in the shop – probably at the bottom moving waste, sweeping the floor,” David Schroeckenthaler said with a chuckle. “It’s been a long time. We’ve all been in the business for a long time now.”

In addition to David and Joshua, family members Anthony Schroeckenthaler and LoRonda Schroeckenthaler also are employed with the bindery as a machine operator and human resources manager/office assistant, respectively. Dillon Bindery also has 20 employees, many of whom have been with the company as long as the second- and third-generation family members. “We have very little turnover,” Joshua said. He attributed that longevity and loyalty with the company’s flexibility and the knowledge that they aren’t just employees. “We make them feel like they are part of the team.”

Camera-Based Inspection Systems Add Quality Assurance to Print Finishing

February 1, 2013

by Dan Desmond, Standard Finishing Systems

Up until a few years ago, those of us in the print finishing industry only recognized inspection systems as being applicable to the mailing segment of the marketplace. Nowadays, we find camera inspection systems on print lines, sheetfeeders, saddlestitchers, perfect binders, paper folders, casing-in machines and the list goes on. The use of camera technology over reader technology has made much of this possible on almost any type of equipment and has allowed these systems to perform verification of materials imprinted with virtually any standard symbology.

Within any camera-based integrity system, the number of and relative position of the camera(s) within the production device will dictate the system’s functionality. That being said, it’s really not the cameras that provide inspection; it’s the software. The cameras merely capture the image for the software and then the programming takes over.

Web Inspection Systems

In a web inspection device, a line scan camera typically is used to verify integrity of each page on a printed roll. When placed on the web (at least one per side), these line scan cameras function more like movie cameras, taking continuous images as the paper is printed. Marks on the web are read by OMR detectors, indicating the top or bottom of each sheet so that the software can display “pages” uniquely and create stopping and starting points for comparative analysis.

Web inspection system designs vary predominately by the number of cameras required to read the full web front-to-back, the type of feed-through of the web (passive or controlling speed) and of course, the user interface and software. These web inspection devices can perform many quality and integrity checks simultaneously, including barcode and MICR grading, color tolerance, pattern matching, white space verification, ink or toner spills, voids, jet-outs and more.

Ultimately, the job of the web inspection system is to read each of the pages generated for specific areas of quality interest, as defined by the operator within the given software limitations, and perform any one of the following actions at minimum:

Stop the printer line to a soft shutdown.
Alert the operator by way of warning lights that errors are present or have exceeded their threshold.
Divert error-laden pages into the waste bin.
Capture data for sheets/packages with quality flaws.

Either built-in or through separately purchased software packages, the best web inspection systems are going to collect the data of passed or failed documents. Other options may include integration with ADF (Automated Document Factory) workflows and/or communication to and from inspection-equipped finishing devices downstream to alert the machines of inferior quality packages that should not be processed or diverted.

Saddlestitching/Bookletmaking Systems

Within this finishing device, an inspection camera could be placed at several different positions to verify integrity during booklet production. Small cameras are utilized to read a given area of about 2″ x 2″ on each sheet as it enters the accumulator. This technology works with sheet feeders for pre-collated digital output, as well as collating towers, provided that the sheets are fed separately or shingled in their delivery to the accumulator.

First, the camera looks for a coding regimen that would indicate the total sheets to be found in the set, which sheet of the set it is and its unique package identifier to indicate that they all belong to the same set. As the predetermined criteria are reached within the software, the set is passed along as a “package” to the next station. If the established criteria are not met, that package either is stopped or diverted based on the saddlestitcher’s functionality. Either way, that package is marked as invalid and should be destroyed by the operator.

This coding regimen usually is accomplished within a string of letters or numbers in OCR-A or -B font, with a universal 1D linear bar code or 2D data matrix bar code. Within the software, the operator defines what characters within the string signify a specific property.

Additional cameras can be placed ahead of reject trays – if the saddlestitcher has them – or at the output end of the trimmer for final production verification.

Perfect Binding Systems

On a perfect binder, the base system consists of two cameras. The first camera reads the code on the cover; the second camera reads the code on the book block. The programming defined in the software will determine if the cover is a correct match for that specific book block and enable the binder to complete the binding process. If there is no cover match, the binder is inhibited from cycling until the error is corrected.

The positioning of the cameras and the reading areas also can guarantee that the cover has been loaded in the correct orientation and that the book block has been placed into the clamp properly. This capability has far-reaching benefits within a plant when using the vision system for even longer-run static work (versus just personalized and regulated work). By identifying improperly assembled books, the system virtually can eliminate materials waste after makeready, leading to productivity improvements and increased customer satisfaction. Additional cameras can be added to verify that the assembled book has exited the binder or three-knife trimmer for final product verification of the complete process.

Mail Inserters

Camera inspection systems typically are used at two or three positions within a production-level inserter. The systems can be used at the primary feeder for static or variable page sets to ensure that all sheets of a set are there and in order. If the inserter is capable of intelligent inserting, this is the location where the code would be read to tell the inserter which of the insert pockets should feed to add specific inserts related to the primary document or recipient.

If the inserting job requires that the primary document be matched with recipient specific materials from that side pocket, then a camera would be added to the transport or insert pocket so as to read the code embedded on that piece to connect it to the primary document.

A final inspection camera typically is used in inserter applications to verify that each envelope is filled with the recipients’ documents. This viewing is done through a window envelope.

Camera Systems Offer Unique Benefits

One of the big advantages camera systems offer over specific bar code reading systems is that they are adaptable as to the type of symbology they are going to be reading. Camera systems read virtually any standardized symbology, whereas 1D readers only can read 1D code, 2D readers only can read 2D code and so on. Camera systems also provide the ability to read OCR characters, MICR, addresses, Blob, images (pattern match) or even OMR markings at the click of a mouse.

The unique versatility is brought on by the software and programming of the PCs or the cameras themselves. Camera systems that utilize a separate and independent light source can be configured to read any of the standard symbology and the OCR, MICR, addresses and images printed with invisible ink.

Another big advantage for camera-based systems is that they utilize a PC to do the analysis and control much of the finishing device. The systems can be integrated into the network workflow, which can provide several production management benefits. With this type of PC utilization, operators can be informed quickly and in great detail as to what the failed integrity event was that just occurred and look back at and review the images captured from that event. A system built with simple barcode readers typically does not capture images and does little, if any, reporting for the operator.

The PC that is an integral part of a camera system can compare the results against an imported data file and update that file with individual sheet or package status so as to provide the following:

Full audit trail on book or booklet assembly completion for regulatory purposes,
A document reprint report,
Production data for SLA performance validation,
Production data for measuring operator performance and
Production data for equipment performance.

Some of the more advanced systems can provide for emailing daily production reports or enabling management to review real-time production results through secure web connections. One even has an iPhone application that can let operators view production data anywhere and anytime.

Dan Desmond is the business manager for Inspection Systems at Standard Finishing Systems. In this position, Desmond works with customers and prospects to insure that production runs operate at maximum efficiency while delivering 100-percent document integrity. Standard Finishing Systems is based in Andover, MA and celebrated 100 Years of Finishing Strong in 2010. A leading supplier of print finishing systems, paper handling equipment, mailroom and reprographic products, Standard utilizes a network of independent dealers and a direct sales force in the United States and Canada. For more information, call 877.404.4460 or visit the Standard website at www.standardfinishing.com.

Folding Machinery Programmed for Efficiency

February 1, 2013

by: Staff

As binderies look more and more toward automation as a cost-saving measure, new technologies are being developed to meet this need. Job Definition Format (JDF), an XML-based file format that serves as a single source of real-time job data, is one such advancement. While JDF doesn’t mandate a given workflow, its flexibility allows a printer of any size to work with vendors to design a workflow appropriate for its needs.

The first version of JDF that could be implemented by vendors was released by the International Cooperation for the Integration of Processes in Prepress, Press and Postpress Organization or “CIP4” a little over a decade ago and the first JDF-enabled products hit the market at drupa 2004. A case study conducted at GRAPH EXPO 2008 showcased the first-ever successful end-to-end live JDF workflow collaboration between multiple vendors. Since then, manufacturers have been offering the technology, but have yet to release a full implementation in the marketplace, said Mark Pellman, director of sales and marketing for the Baumfolder Corporation, Sidney, OH.

He said the use of JDF technology really depends on the size of the operation. “We see only a few smaller operations utilizing the benefits, and some larger binderies do, but implemetation has been limited.”

Pellman offered his take on the latest technology to hit the folding industry and what to expect in the coming years.

What other advances have been introduced to the folding industry?
We are seeing customers using folding machines to produce more specialized folded products, including heavier stocks with multiple panels that traditionally have been limited to a simpler knife folder. The adaptation of various glue systems and attachments helps create attractive folded products that add value to direct mail, special promotion pieces, etc. Gluing systems have advanced to the level that they can add special cards and other items on a folding machine with great accuracy and verify that the glue line was placed for each piece.

Have digital printing and shorter runs necessitated changes in folding equipment?
Many manufacturers saw this change coming years ago and have adapted product lines to meet these needs. One recent change is the ability of a single digital print engine to produce a 14×25.5″ sheet for short runs, and the equipment manufacturers have responded by introducing folders with the capability to feed and fold this size of sheet for the short-run markets. It’s also important to be sure folding roller and fold plate technology are prepared to prevent marking in a digital environment and reduce static.

One way BAUM has adapted to the need to reduce static is with new urethane coatings on suction wheels and the use of state-of-the-art coatings on the feed tables and platforms to reduce static build-up.

Folder technology has kept up, but what about feeders and joggers?
New feeding technologies had to be developed as well to include sheet staging capabilities and utilization of PLC controls to adapt to more inline applications. Feeders have had to adapt to do more than just feed paper to folding machines. New feeder solutions are available for feeding inkjet bases, diecutters, UV coaters, print engines, packaging lines and more.

Do you foresee a point in which folding machinery will require zero human intervention?
We would love to have this, but the marketplace will probably not want to pay for the price of a machine with this level of automation. Manufacturers are producing folding machines with less setup and operation, but the variations in printing/imaging, grain direction, stock weights and other factors still create the need for human intervention. Another key area is the setup of perforating, scoring and slitting. Even though many manufacturers offer automation and “information” on their folding machines, a high skill level is required to set up the slitter shafts for a successful job run. One solution is to provide cartridge slitter shafts that can be easily removed and replaced with another set of pre-set shafts for the next job.

What’s next? Where do you see the folding industry in the next 10 years?
We see more inline and near-line folding applications being utilized. We also see our customers wanting to use the folding machine for more than just folding. A folder can be utilized more as a feeder and scoring/creasing/perforating machine while being run inline with other equipment. The increase in personalization of printed/imaged products also will require the folding machines to adapt to more sophisticated monitoring devices to insure the folded piece is accurate for each recipient.

It also will be important to review and adapt to the needs of customers that have multiple printing and imaging technologies from various manufacturers. There will be a need to continue to simplify the setup and operation of folding equipment to adapt to a newer workforce that is more digital in nature and companies that strive to compete by lowering their costs with easier-to-operate equipment.

Looking into the Future of Loose Leaf Production

February 1, 2013

by Jen Clark

The ability to store and easily modify or amend information over time is what makes loose leaf binding an attractive option for many bindery clients. And, while some loose leaf notebooks may include special features, the basic design of a loose leaf binder has remained the same since the first patents for the device were filed in 1854. However, the options for the construction materials have changed.

Cover Material Varies Depending on Budget, Purpose
Most loose leaf binder covers are made of three pieces, similar to a hardcover book, but are produced in many styles. Vinyl binders are popular because they are durable and economical. They are manufactured using vinyl sealed over chipboard.

“There are different kinds of vinyl,” said Joe Lauricella, vice president of Gane Brothers and Lane, Elk Grove Village, IL. “Film vinyl comes in many different gauges, grades and aesthetics. While vinyl is popular, we are seeing inquiries coming in for phthalate- and lead-free vinyl – more ecologically friendly items, especially for our California customers,” he said. “Vinyl is common within the loose leaf trade, but competes with the popularity of other options available for turned edge applications.”

Turned edge binders are manufactured using a variety of materials, including book cloths, imitation leather and high-strength paper wrapped around board. “Popular items are B cloths =- depending on how they are filled or impregnated gives it strength,” Lauricella said. “C grades are a heavier cotton cloth, also filled and impregnated. It can go up to F grade buckrams – a polyester-cotton blend. We also use imitation leather – Sturdite, a heavy cotton sheeting embossed to appear like leather. It is used quite readily in the trade for turned edge projects. Genuine leathers are used too. Bonded leathers are reconstituted leathers held together with a binding agent. They can be colored and embossed.”

An option from Gane Brothers and Lane’s premium line is the warm, soft texture of natural cork for a decorative covering material. “Anything that you can turn edge or laminate, you can use for cover material,” Lauricella said. “People have made binders from wood – from the board itself – and even metal.”

Budgets always play a role in what customers choose, he added, but the products are specified by the end-user. “We stock, and have the ability to provide all kinds of turned edge and heat seal products,” he said. “We are unique in that we sell and promote all of these products and can make recommendations when customers are looking for a specific presentation to match an economy of price and performance. We provide a different kind of service. Our question to the customer is ‘what are you making, what are your desired performance characteristics, what kind of visual do you want, and what is your budget?'”

Gane Brothers and Lane also offers complete converting capabilities. “We can cut to size, sheet material by width, slit roll goods, cut board, drill, round corner and shrink wrap,” he said. And while the company doesn’t offer decorating services, such as foil stamping, screen printing, embossing and debossing, the sales staff is knowledgeable about the various decorative methods. “There are some really cool, neat-looking things that can be done to decorate a particular material surface,” Lauricella said.

Plastics Gaining Ground, but Metal Remains Popular Choice for Rings
The spring-loaded metal clamps, otherwise known as ring metals, utilized to hold and organize documents are made of highly polished nickel-plated steel. The rings often are circular or D-shaped, while others utilize rods to contain the paper. Some manufacturers now are offering plastic three ring binder mechanisms in a variety of colors.

Spiral James Burn, Totowa, NJ, offers plastic rings made from ABS Resin. “When molded, it forms into a very durable product with a smooth finish,” said Michael Bossard, integrated marketing manager. “This material also assures you that the rings won’t rust and makes them archival safe.”

While plastic rings allow for more color choices, which help projects stand-out, they are limited in how much paper they can hold. “Ultimately metal can support more weight, so for particularly large projects metal will hold up better,” Bossard said. “If the application requires a larger ring size, then plastic would not be the best option.”

Plastics rings also cost more. “Metal is mass-produced and essentially a commodity at this point in the product life-cycle,” Bossard said. Metal rings come in a variety of shapes to accommodate large-capacity storage. Round rings offer the easiest page-turn and accessibility, while D-rings accommodate more pages. Trapezoid-, elliptical- and arch-shaped rings are also available from some suppliers.

Index Tabs, Pouches Help with Organization, Archiving
Among the special features employed with loose leaf binders are index tabs, pockets and sheet protectors. Pieces of card stock with a tab at the edge allow the binder’s contents to be broken into sections. Pockets that are attached inside the front and back cover of a binder are used to carry items such as CDs or business cards. Sheet protectors can hold printed pages and are attached to the rings, providing archival qualities.

The Holmberg Company, a Minneapolis, MN-based supplier of converted paper products, offers standard and custom-printed index tabs in a variety of styles, including Mylar lamination in clear, write-on and in 23 different colors. Fileback tabs, in high demand by the medical, financial and legal industries, also are available.

“Most index tabs are produced in much the same way, but that does not mean it is an easy product to produce,” said Jasmine Kuipers, Holmberg product manager. “The difference comes in the quality of the finished product and the service provided to the customer. We have been making index tabs for over 50 years and our customers know that our tabs will always be collated correctly, with no missing tabs; have clean, dust-free edges; and will be packaged carefully to prevent damage or production issues.”

Indent paper is pre-reinforced paper designed specifically for the index tab manufacturer, and digital or offset printer. Holmberg developed Indent paper to create high-quality reinforced index tabs. “It features a strip of polyester film to protect the sheet from tearing loose when put into a ring binder,” Kuipers said. “Indent reinforced paper also is different from other reinforced papers because the polyester film has been ‘indented’ into the paper so there is no build up – or stack bias – and it lies flat for feeding into your press or copier.”

In addition to a wide range of stocked products, it also manufactures non-standard sizes and reinforcing formats to meet the sheet and printing needs of its customers. The fileback tabs and folders, commonly used in doctor’s offices, have an attached metal prong which allow other documents to be attached to the tab. “The goal of the fileback is to allow easy access to multiple documents without taking up much room,” Kuipers said. “Filebacks are primarily used for record-keeping purposes, not presentations.”

There are two materials used most often for sheet protectors – polypropylene and vinyl. Both offer different benefits depending on the presentation. Polypropylene sheet protectors are considered an archival material because they are an acid-free means of permanent storage. Inks and other materials won’t stick to the sheet protector. It also is thinner and more durable, constructed of a lighter gauge than vinyl while maintaining the same durability and toughness. Vinyl sheet protectors offer a traditional look and heavy feel, but aren’t as durable as polypropylene. Restaurants often use vinyl sheet protectors to hold menus because its heavy feel gives a sense of weight to the presentation.

Vinyl Art, Inc., is a Minneapolis, MN-based manufacturer of flexible packaging and loose leaf products made from vinyl and polypropylene. Adding pockets or pouches to binders can enhance presentations, said Tim Hitchings, the company’s vice president. “It allows the customer information to be displayed for use. It also saves binder manufacturers money when they forget a pocket. With proper use, the pockets or pouches can be very durable,” he added.

In addition to in-house manufacturing, VinylArt also offers specialty finishing services such as de-bossing, foil stamping and silk screening on items in vinyl, he said. “We offer custom manufacturing in sizes up to 19½x35½” and can make items in any available vinyl material in clear, colors, tinted clears, frosty and adhesive-backed.” The adhesive pockets are manufactured with general purpose adhesive, glass clear fronts and easy recessed openings, Hitchings said. The adhesive can be permanent or repositionable.

While the general construction methods for loose leaf binders have not changed, the materials used both inside and outside of the information delivery system will continue to evolve to meet user needs.