Automation

Duplo Offers Automated Digital Print Finishing

July 13, 2018

PostPress

A new sheet feeder from Duplo USA, Santa Ana, California, is among the company’s growing range of booklet systems along with its slitting/cutting/creasing solutions.

The DSF-6000 high-speed sheet feeder is configured with the DBM-600 bookletmaker and processes pre-collated digital or offset documents at a rate of up to 600 sheets per minute. In partnership with Ricoh, the 350R inline booklet system integrates the Duplo DBM-350/T bookletmaker and trimmer with the Ricoh Pro C9100/8100/7100 series of production printers. Additionally, the DC-746 slitter/cutter/creaser offers new features, including optional rotary tool and cross perforating modules, both with strike-perforating capabilities.

For more information, visit www.duplousa.com.

The Case for New Bindery Equipment

December 18, 2017

by Melissa Larson, contributing writer, PostPress

Muller Martini’s InfiniTrim is an example of today’s intelligent bindery equipment significantly increasing productivity and throughput.

To longtime observers of the printing industry, finishing operations sometimes were referred to as the overlooked stepchild. Shops that had successfully made the transition to digital printing still were working with post-printing set-ups that had become antiquated almost overnight.

That’s changing quickly with the swift evolution of automated bindery equipment, which has become a necessity with the increased number of shorter runs, the shortage of skilled workers and mounting labor costs.

Printers find themselves smack in the middle of many of the global trends that are driving plant floor automation. Among these are a lack of skilled labor, reductions in operating costs and rising customer demand for flexible automation together with consistent quality. Also, although it may not seem like it when you’re contemplating a million-dollar purchase, the cost barriers to automation are falling.

The BindRite Dealers Association holds an annual meeting and vendor tradeshow to showcase the latest in print bindery and finishing, specialty printing and custom presentation equipment and supplies. During the meeting, and throughout the year, the association facilitates the exchange of information regarding member activities in marketing, sales tactics, technical service management and general business management practices. Additionally, the Dealers Association assists members in product and vendor searches. It has compiled a group of BindRite-branded products, including equipment and consumables.

Green buttons

Al Boese, BindRite executive director, has closely tracked the evolution of bindery equipment over the years and has commented on a machinery trend he calls the Green Button Revolution.

“What is the Green Button Revolution? Basically, it is the next stage of automation in digital printing, and it now is beginning to affect all phases of paper handling, binding, protecting and the other print finishing processes,” said Boese. “Green Button means that worker intervention is minimized; in its most ideal form, the operator merely needs to load the machine and press a button (which most often is green).”

Using data taken from the National Print Owners Association (NPOA), Boese has established that labor costs are the single greatest category of business expense in postpress operations, overtaking overhead as the greatest drag on profits. “In fact, with overhead and cost of sales remaining relatively stable over the last 30-year period, the uptick in labor costs comes almost directly out of owner’s compensation,” he explained. According to Boese, these findings account to no small degree for a surge in sales of automated finishing equipment.

“Highly automated bindery equipment is engineered to provide optimum ROI because of its unparalleled efficiency, shorter run capabilities and built-in quality controls,” explained Werner Naegeli, president and CEO of Muller Martini North America.

“Unlike legacy machines, which were designed with gears and chains, each component in today’s digital machines is individually servo-driven. Not only does that help achieve maximum production speed, but it also optimizes each production stage, allowing for machine set-ups and adjustments that require little or no manual intervention.”

And, this type of automation is available today for both inline and offline bindery equipment. For print binderies and finishers, automation may be more important for its offline bindery equipment than for their customers’ inline possibilities.

“Not all digitally printed materials are going to be practical for binding and converting inline,” stated Boese. “Because of this, trade binderies and finishers must have current, automated equipment to service the difficult projects in a timely and cost-effective manner. Old, out-of-date bindery equipment will simply not survive.”

Time to forget the ROI?

Occasionally, the ROI number crunching must take a back seat to the long, hard process of imagining what the future will look like for a particular business. Chris Eckhart, president of Eckhart and Co., a full-service binder in Indianapolis, Indiana, and also a manufacturer of custom packaging products, recently purchased a Kolbus perfect binder. This technology represented a multimillion-dollar investment; however, the decision was driven by more than money considerations, Eckhart explained. Looking to the future of his business, he stated: “To survive and be profitable, we concluded that we needed to invest in the technology that was available in our industry.”

Crunching the numbers for such a purchase, from an ROI standpoint, made no sense. “It was impossible to justify the ROI. I thought that with the greatly increased efficiencies of the new machine, we might be able to go from two shifts to one,” said Eckhart. The Kolbus’ set-up and makeready time is orders of magnitude faster than the previous equipment and runs at much faster speeds. But at the time of the purchase, it was hard to predict whether the greater efficiencies would mean loss of work hours for Eckhart’s staff.

As it turned out, so much new business rolled in that the reduction in hours never happened. The increased quality of the new binder’s output and the enhancement to Eckhart’s reputation made for new and happier customers.

And, there were other “soft” advantages that were not so easy to quantify. “We proved to our employees that we were committed to spending that amount of money to improve the reputation of the business,” said Eckhart. “Also, they are proud to have been trained on state-of-the-art machinery.”

The use of intelligent automation in today’s bindery equipment can significantly increase productivity and throughput in other ways as well. As a case in point, a book-on-demand provider in Germany utilizes Muller Martini’s InfiniTrim three-knife trimmer, which offers the complete automation capability so essential to achieving optimum productivity when processing ultra-short runs.

When comparing the InfiniTrim’s performance to a classic three-knife trimmer, the customer noted that 795,000 format changes have been performed on the InfiniTrim in one year. If those format changes were done on a classic trimmer, it would have required over five years of makeready time.

As Boese points out, however, theres more to the equation than just the purchase price. “Buying decisions are made, or should be made, based on the availability of the local supplier or dealer to support the equipment being purchased,” he said. “Support includes installation, operator training, technical service, spare parts and just being there when the need arises. While many focus on the initial cost of a piece of equipment, it is the total cost of ownership that counts, and that includes local service and the uptime of the operation.”

Contemplating the future

A 2015 report from Smithers Pira, a consulting and market intelligence company with US headquarters in Akron, Ohio, examines the current state of the commercial printing industry around the world going forward to 2020.

One summarizing statement includes the following examination of the print industry: “A number of technological developments have improved efficiency, contributing toward declining levels of employment within the industry. Rising levels of automation are being seen in both administration and print production, and printers have sought to invest in a range of areas to shore up profitability and compete more effectively. This, too, has led to increasing consolidation within the industry.” Printers are left to wonder what part their businesses will play in that consolidation.

Naegeli is firm in his conviction that new bindery technology is a must in today’s world in order to survive and stay competitive. “Since it’s not unusual for a printer to receive 200 orders containing just 20 to 40 runs each, an effective bindery solution must be able to process these files quickly. So, without investing in automated technology, it’s almost impossible to process digital print jobs efficiently,” he said.

Naegeli went on to explain, “Most importantly, customers want the flexibility to produce innovative products and promotions that offer personalization and other variabilities (e.g., format changes, hybrid products, multiple versioning in run lengths, etc.) that increase end-user engagement and response rates. And, they are seeking printers that not only meet their demanding deadlines, but deliver a consistent, high-quality end product. For most printers and binderies to remain relevant and robust, they need singular finishing capabilities that can produce a wide range of complex printed products.”

For Eckhart, it’s a matter of practicality. “At some point, equipment just wears out,” he stated. “Then you have to make a decision about the future. For the past 10 to 15 years, companies in this industry have survived by cutting hours. It’s time to think about adopting a strategy to re-invest in the business, because those are the companies that are going to continue to survive. The alternative is to go out of business.”

Boese put it succinctly: “Time is saved because the user interface is intuitive and simple. Many standard jobs are pre-programmed, and custom work can be stored for future use. Job set-up is simple, swift and precise. Machine operation during a job run is automatic, freeing an operator to prepare the material for the next job or other multitasking activity. Likewise, material is conserved because makeready essentially is eliminated, and a perfect result usually is achieved on the first sheet or book. Green button technology is alive and flourishing, with even more potential for the future.”

Understanding the Flow of Inventory Management

September 8, 2017

by Grainger Editorial Staff

Is a large percentage of your company’s dollars going toward inventory? Managing inventory efficiently can help cut down on many costs that you may not even be aware of. Poor inventory control can lead to emergencies, such as running out of much needed materials. This can take time away from production, and finding a quick replacement part can be expensive. On the other end, an overstock of products can take up valuable shelf space and lead to unnecessary purchase costs.

Knowing the flow of managing your inventory is the first step to getting a better understanding of how inventory control works and how you can manage your inventory properly.

Types of inventory

Different facilities keep stock of different items to fill different needs. Because hospitals are service-based businesses, their inventory will mostly consist of items needed to perform medical care. Bandages, disposable gloves, thermometers, even surgical tools – these are all items that must be available for everyday use.

Manufacturing plants, on the other hand, will have a strong inventory of production materials. Sheets of steel, plastics, parts for assembly – these materials must be on hand to keep business running. Retailers also carry a high inventory of items waiting to be sold, and running out means missing out on potential revenue.

Other industries, such as hotels and offices, may not need as large an inventory as manufacturers, retailers and hospitals, but they will have an inventory of maintenance, repair and operations (MRO) items. Light bulbs, reams of paper, ink cartridges, fuses you name it – this all contributes to an inventory that costs money to purchase, store and use.

The flow of inventory

Regardless of the type of inventory your business is handling – whether it’s for service, manufacturing, retail or maintenance – there is a common flow that can help you manage your inventory better.

Purchase
An initial purchase must be made to get things going. Unless your facility is an expansion, your first purchase will be based on your best estimate. In order to make the best guess possible, try researching what other facilities like yours are using and in what quantities. For your first buy, it is better to err on the side of caution – this is one time where having a little too much won’t hurt. This will allow you enough wiggle room for mistakes, but be sure to allot enough storage space for surplus.

Store
All the items you purchase have to go somewhere. You will need enough storage space, as well as an organized system in which your on-hand items are easy to find and get to. Time spent searching for an item or traveling to and from the storage location is time that is taken away from your business.

Use
Congratulations! You’re in business. That means that items that have gone into your inventory are now being taken out. One by one, the items are removed from their storage location and are sold, used or fabricated – whatever the case may be. In this stage, the items are being taken for their intended use.

Tracking
As items are purchased and used, it is essential that they are properly tracked. A system must be in place in order to know, at any given time, how much of a particular item you have on hand. This way you will know when your supply is low and needs to be replenished.

Reorder
Once an item has reached its reorder point, it is time to replenish your supply. This can be done manually or through automated systems.

Forecasting
Once you have used, tracked and reordered a few times, it is possible to start forecasting your future needs. This is a proactive attitude toward your inventory in which you take control of what to bring in ahead of time, rather than waiting for your supply to deplete and reacting after the fact.

Common management pitfalls

Just as inventory flow is similar among industries, so are the common issues that cause costly inventory problems. Being aware of common problem areas can help you avoid potential (costly) mistakes.

Lack of automation
With computerized options available to track, forecast and reorder items for you, there is no longer a need to miss a needed reorder. Manual tracking takes time, and even the most skilled data-entry person will make mistakes. There always will be a gap between updating records and the real-time use of your products.

Improper training
Any system you have in place for tracking your inventory won’t amount to much if the people responsible for keeping those records arent using it. Inventory software users should be fully trained on the program, and the workers using the inventory must be trained on how to account for the items that they use.

Picking inefficiency
Efficient organizing of your facility’s space can make a world of difference in your productivity. How much time are your workers using to get to the items they need? How difficult is it to get from the point of production (or sale, or service) to the storage space? How easy is it to find the most used items on your shelves?

Infrequent cycle counts
Yearly cycle counts represent a costly and ineffective way to reconcile what you think you have with what you actually have. This usually involves shutting down operations for a day or two to take your inventory counts for all the items you stock. More frequent cycle counts on specific areas can be more cost-effective and will keep a regular tab on what you have on hand.

Sources

http://mhlnews.com/warehousing/top-5-solutions-common-inventory-management-mistakes
https://www.entrepreneur.com/article/252704
http://www.dummies.com/business/accounting/how-to-track-inventory-flow

Reprinted with permission from Grainger. The information contained in this publication is intended for general information purposes. No representation is made that the information or references are complete or remain current.

The Future of Finishing: The Evolution of Print – and Printed Products – Demands a New Finishing Paradigm

June 14, 2017

by Andy Fetherman, vice president of sales and technology, Muller Martini Corp.

The Presto II Digital enables printers to saddlestitch personalized and hybrid products, both conventional and digital inline.

Nearly six centuries ago, German Johannes Gutenberg invented the first printing press. Many point to this development as the beginning of manufacturing, since inventors began looking for new ways to make production more consistent and faster. Yet, the concept of streamlined processes didn’t get the attention of most industries until the beginning of the Industrial Revolution in the late 1760s. Today, the manufacturing process continues to evolve.

Many futurists believe we are now experiencing a “post-information” revolution. Coined “Industry 4.0” or the “Internet of Things (IoT),” it is considered the next phase in the manufacturing process. At its essence, IoT is about connecting any device with an on/off switch, including machine components, to the internet, as well as to each other. The result? A digitized manufacturing process that communicates and deciphers data to achieve intelligent decision-making. Whats driving the Internet of Things?

Rapid increases in the ability to create and store data
Significantly greater computer power and connectivity
Advancements in how humans interact with machines, such as touchless interfaces and barcode readers

Concurrently, game-changing advancements in the graphic arts industry, such as inkjet technology and digital print manufacturing, have produced an extraordinarily complex finishing process. Today, not only are customers demanding both long and short runs, including runs of one, but they also are seeking high levels of personalization and customization for their products. So, the challenge facing finishing manufacturers is simply this: to provide printers with leading-edge solutions that feature the systems, machines and software that welcome, accommodate and exploit the Internet of Things.

Today, finishing operations – whether through a trade bindery or finisher, or within the printing operation – must embrace IoT and understand it will continue to become an important part of manufacturing and the printing/finishing world. Muller Martini’s manufacturing philosophy, trademarked Finishing 4.0, features five precepts that not only represent the future of finishing but also are integral to the design and engineering of a finishing manufacturer’s portfolio.

Automation. Although automatic control of machine processes dates to the 1940s, the emergence of barcode readers in 1974 truly legitimized this advancement. And today’s increased demand for variability dictates that highly intelligent automation be present within every phase of the printing process.
Interconnectivity. Barcodes embedded on the product during the prepress imposition process provide linkage throughout the entire production line. Not only does this help streamline (and greatly lessen) makeready, automate processes and eliminate human error, but interconnectivity provides actionable, real-time data for on-the-fly decision-making.
Variability. A variable world requires efficient production and finishing of variable end products, independent of their thickness, format, content or trim and run size. Likewise, content integrity and validation from book to book to book is a crucial component.
Touchless workflow. Requiring a high degree of interconnectivity, a barcode-enabled touchless workflow facilitates uninterrupted print finishing with little or no manual intervention, thereby reducing labor and waste.
Hybrid systems. The processing of both offset and digitally printed products on the same machine – either separately or concurrently – necessitates scalable systems that are engineered to expand as your business evolves and grows. Hybrid finishing solutions not only provide commonality in quality but optimal production efficiencies. In addition, they offer significant investment protection, allowing you to add features and functions as digital and hybrid opportunities increase.

To successfully compete in today’s – and tomorrow’s – variable world, binderies/finishers and printers must embrace forward-thinking finishing solutions that efficiently and expeditiously accommodate offset, digital and hybrid printed products. Operations must be designed to embrace these challenges with end-to-end workflow from file to finished product that achieves the greatest quality – and even greater efficiencies. These efficiencies include reduced makeready and manpower, less waste and faster speed to market, all while significantly improving the experience of the product’s end user.

At the end of the day, the future is all about ultra-efficient finishing – and enhanced profit potential. So be sure to consider these five pillars – automation, interconnectivity, variability, touchless workflow and hybrid systems – when you choose your finishing partner. And be extra sure they are as committed to growing your business as you are.

Andy Fetherman has more than 30 years of experience within the graphic arts industry, beginning his career in 1986. He joined Muller Martini in 1994 as product manager in the Press Division. For the past 15 years, he has been spearheading the development of digital finishing systems for print providers worldwide.

Decorating and Finishing Keep Up with Digital Label Printing Technology

June 14, 2017

by Jeff Peterson, editor-in-chief, PostPress

The Mark Andy Digital Series integrates label production into a single-pass workflow, allowing for greater flexibility.

We all know that digital printing has infiltrated virtually all aspects of the printing marketplace. The production and printing of labels is no exception. Possibly the most interesting aspect of label printing presses has been the creation of what is characterized as “hybrid” presses, where the label press is built to utilize both flexo and digital printing technologies. “The growth of this trend in digitally printed labels specifically played a significant role in our development of inline hybrid solutions,” stated Jill Smith, marketing manager for Mark Andy, Chesterfield, Missouri.

With the growth in digital printing for short- to medium-run labels, and the emergence of hybrid label presses, a need has been created for decorating and finishing solutions to fit the digital format. Press manufacturers have developed both inline and offline converting/finishing solutions that can offer everything from diecutting and hot and cold foiling to UV coatings and laminates. “With the growth of digital printing, there continues to be more options and features with digital finishing,” explained Jim Kehring, strategic partner coordinator for AB Graphic International Inc., Elgin, Illinois. “Customers are finding great flexibility in new digital finishing technology.”

Telstar Engineering’s Offliner® Web Transport Platform performs critical register/re-register with built-in servo-driven unwind and rewind units and can support various finishing modules.Telstar Engineering has been developing digital finishing machinery for several years for a variety of narrow-web customers. This led to the design of its Offliner® Web Transport Platform. This offline finishing machine allows printers to operate the digital printing press for other jobs while decorating and finishing operations can be completed on the original job. The Offliner actually allows narrow-web printers to take in jobs from other printers that do not have this type of offline capacity. The Offliner performs critical register/re-register with built-in servo-driven unwind and rewind units. The platform can support various finishing modules including cold foil, lamination, Cast & Cure holographic, rotary screen and diecutting. It can even be mounted with digital print heads, switching the process to “finishing with digital.”

“We have shown many traditional label printers that they can thrive in the digital world and offer a variety of decorating and finishing techniques as well,” stated Tom Kirtz, president of Telstar Engineering.

Mark Andy has developed a line of hybrid press offerings, including its highly configurable Digital Series platform, to create flexibility for its customers. The Digital Series offers the ability to run both flexo and digital print inline concurrently and includes inline modules for options such as cold foil, lamination, coating and inline diecutting. “By integrating all aspects of label production into a single-pass workflow, the resulting savings on time, waste and labor are significant,” explained Smith.

The Digital Series hybrid label press is a true production-level digital solution that runs high-quality consistently at speeds of 240fpm (73mpm). It is available in a printing width of 13.25″ (336mm), supports repeats for flexo print stations from 5″ to 24″ (140 to 610mm) and is supported by Mark Andy’s digital front end ProWORX (powered by Esko). The Digital Series is engineered to be highly configurable. It features high-resolution UV inkjet printing and offers top-coating, fully integrated inline flexographic printing modules and a full range of inline converting/finishing options.

ABG International has developed digital decorating and finishing equipment that can provide operations the flexibility to run inline after the digital label printing press or near-line where the finishing operations can be performed separately.

“The best part about running “near-line” is you get to choose by the push of a button if you want to run inline or offline,” stated Kehring. “The length of the run is what usually helps determine this – the goal is to always keep the machine running.”

The ABG International Digicon Series 3 was designed to add value to the operations digital printing technology, including the ability to meet the strong demand for higher speed cutting.

The ABG International Digicon Series 3 was designed to add value to the operations digital printing technology. One of the newest developments for the Digicon 3 is the FAST Track die, claimed to be the world’s fastest semi-rotary diecutting system. The system was developed to meet the strong demand for higher speed cutting with the speed of digital printing presses continuing to increase. Another new addition is ABG’s Big Foot 50-ton capacity hot foil and embossing module that allows multiple foil feeding along and across the web, and raises narrow-web embossing to a new level. In addition, the Digicon 3 can include a Lamination in Register module that produces full width multilayer constructions, allowing for a preprinted web to be laminated to the main web in perfect register.

Gallus has introduced its Labelfire 340 digital printing press, developed with Heidelberg Druckmaschinen AG. This unique digital press features a printing module with state-of-the-art inkjet printing heads and includes inline finishing processes that have been specifically optimized for digital printing. This allows the Labelfire 340 to varnish, foil embellish and further process labels inline – from the roll to the finished diecut label in a single production run.

Integrated Gallus ECS modules support the digital flexibility of the Gallus Labelfire 340 as well. Labels can be varnished, laminated, embellished with cold foil and diecut in a single operation. The conventional modules support the use of primer, spot color, security or cold foil features, varnish or lamination without interrupting production, regardless of the complexity of the label.

Several factors must be considered when determining what is the most efficient way to decorate and finish digitally printed labels. With hybrid label presses that run at maximum speeds, the ability to perform operations such as foil, embossing, laminating, etc. inline can be advantageous. However, offline or near-line options may be a better solution for small- to medium-sized runs or for digital presses that run at slower speeds. The bottom line is that press manufacturers are staying up with the times and providing solutions for digitally printed labels that can fit specific operations and specific applications.

“As the digital revolution continues, manufacturers of narrow-web printing and converting machinery must have the ability to provide solutions for decorating and finishing that match the technology of the digital printing growth,” concluded Kirtz. There seems to be little doubt that this will be the case.

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.

Targeted Bindery Automation

November 21, 2009

by: Brad Emerson, www.fixyourownbindery.com

Efficient operations often hinge on automated equipment that increases production efficiency while also decreasing makeready times. However, these objectives also can be met through targeted automation, rather than through six- or seven-digit silver bullet investments. Improving bindery quality and identifying obtainable returns on investment requires a surgical approach to automating bindery operations.

Automation Options for Bindery Operations

1. Motorized Adjustments
With motorized adjustments being added in almost every industry to save operator footsteps and minimize operator-input errors, remote servo/actuator adjustment is no longer just for the pressman’s ink keys. Automation has migrated into the bindery with predictable and reliable results. While a “lights out” bindery solution is conceivable in a digital plant with an unlimited capital budget, targeted automation of the adjustments routinely used on existing equipment can provide measurable R.O.I.

For example, many buyers making a large capital investment in a new perfect binding line with over 50 servo motors from gatherer through trimmer would be surprised by how few of the motors are actually used on a typical product mix. Many plants do not raise or lower milling units, gluepots, and nipping stations from one job to the next. Focusing automated adjustment on a handful of thickness adjustments could generate real bang for the buck in the vast majority of plants.

Some of the early bindery automation pioneers with retrofit kits on paper cutters have already incorporated the bolt on kits to include modern CIP4 and JDF technology. I would expect this same technology to migrate into future aftermarket kits for saddlestitchers and perfect binders, as well as the use of off-the-shelf motors and control modules where possible.

2. PUR Adhesive Upgrades
We have been hearing for more the 15 years that the glue or adhesive of the future is coming, and that adhesive is PUR. Well, up until a few years ago, you could almost count all the PUR binderies from coast to coast on both hands. Binderies soon learned that PUR was not just a direct replacement of the hotmelt they were currently running. Many prerequisites had to be met before making a successful transition to PUR. Machine wear regarding book clamp guidance, spine preparation, increased daily gluepot maintenance with a given OEM’s gluepot design, conveyor length, and smooth conveyor transitions all had to be factored in sooner or later. Conversions to existing perfect binders often can be accomplished for less than 10 percent of the cost of a completely new line.

Possibly the only growing sector in the printing industry today is the digital market, and you would be hard pressed to find a digital press OEM that would recommend anything other then PUR for reliable binding strength. It seems the sometimes brutal process of digital print combined with the recycled papers of today makes for increased binding challenges. As recently as five years ago it was difficult to purchase a new PUR perfect binder for under $1 million. With many small perfect binders with automation entering the equipment market today, specifically targeting the digital shops, it is possible to purchase a new perfect binder with PUR and motorized adjustments for under $100,000.

3. Bookblock Feeders, Cover Feeders, and Web Bundle Feeders
With the combined use of the Internet search engine and the seemingly endless supply of surplus equipment through closures, auctions, and downsizing, the hard to find add-ons of yesteryear often can be located today. These feeders can be automated, made portable, interchangeable, or permanently added to a line by your own in-house maintenance personnel or a preferred bindery technical partner. A bookblock feeder running bookblocks at the greatest possible speed without the tedious repetitive pace of human labor can increase margins, as well as differentiate a plant from a competitor. The same R.O.Is often can be realized on web bundle feeders, cover feeders, book stackers, in-line mailing, etc.

4. Signature or Pocket Readers
ISO standards, end user expectations, and the need to minimize product-spoilage cost is pushing binderies towards some type of automatic verification of products being gathered correctly on saddlestitchers, perfect binders, or loose inserters. Many binderies have these systems, but choose not to use them due to poor performance or time required to set up and maintain them properly. When choosing an aftermarket system, samples technically approved by a prospective vendor in advance can eliminate many headaches and finger pointing. There really is no system that can be purchased and forgotten about – all systems require plant management and operators to take ownership and commit time to perform routine cleaning, calibration, or maintenance of the system.

5. Training
Beyond the safe-operation training of a given piece of bindery equipment, focused training can trim hours off makeready time and reduce equipment damage and downtime when a plant’s typical product mix is factored into the training. Sharing bound and unbound product samples of the typical product mix in a given plant in advance can allow a professional trainer to tailor a training session with optimal long-term results.

Additional Factors to Consider
All of these above items require an investment, but still pennies on the dollar compared to the complete replacement cost of a new machine. Some careful “crossing of T’s and dotting of I’s” can prevent the same gremlins that hampered production prior to the automation investment from returning once the investment is made. Before writing a down payment check for automation or expansion, binderies should evaluate the decision from several perspectives, including:

Has the machine been evaluated overall by a qualified technician (other than, or in addition to, an OEMs new equipment technician) to determine if the machine is in acceptable mechanical condition? Fully rebuilding a worn gluepot – possibly the highest maintenance item on a used perfect binder – can be less than 1 percent of the cost of a new binding line.
Do the production scheduling associates optimize the schedule for the bindery? Scheduling two jobs of nearly the same size is as efficient as the highest level of automation on even the most prehistoric piece of bindery equipment.
What are the bindery capability “wish lists” of existing customers, new prospects, and team members?
Should an independent bindery consultant with experience in bindery production and automated equipment provide a report and recommendations?
Are the current operators properly trained on the most difficult products you produce?
Do the machine operators have the proper manuals and documentation?
Is this the best time to rethink the machine and/or entire bindery layout?

Brad Emerson is the general manager of www.fixyourownbindery.com, a company specializing in consultation, turnkey new and used equipment, automation, equipment fabrication, and training. Emerson’s bindery background includes bindery supervision, as well as marketing and consultation with a global bindery equipment leader. For more information, email brad@fixyourownbindery.com.

Why Automate the Folding Function?

November 21, 2007

by Mark Pellman, BAUM

The need for automating and/or improving the folding process has become more prevalent today than ever before.

Shorter run lengths can require more frequent setups.
The emergence of digital short run printing has changed the imaging process but the need for bindery and folding is still there.
Less setup time saves cost.
Skilled bindery labor is harder to maintain due to a lack of trained personnel and the depletion of a generation of bindery operators.
Off-shore and other outside sources are creating costing pressure requiring bindery work to be more cost competitive.
The ability to repeat jobs quickly with minimal setup is key to keeping costs low.

How to Determine What Level of Automation is Required

Automation can add considerable initial equipment cost to bindery equipment. Completion of a payback or return on investment plan is critical before purchasing automated equipment vs. manual set-up equipment. Note that all processes required for folding cannot be automated. Many automated bindery machines can claim a fast setup, but is the setup accurate for a quality job?

A complete list of current and anticipated work for the folder should be made to determine if automation is needed. If you are running signatures for books and rarely are making changes to the fold, automation may not benefit your particular job mix. If you are running several short run jobs with frequent changes, automation will pay for itself.

After determining that you have several set-ups, determine how many operators you currently use and how many you might be able to use if automation were added to the process. Determine the skill levels of your operators and match their abilities to the automation to ensure that the investment will pay.

It is important to completely evaluate all the needs for the equipment. All automated folders are not equal. Quick set-up of foldplates (and other guides, etc.) is great for making creases in the paper.

You also must analyze other applications, such as for scoring, slitting and perforating.

Can the folder score heavy stocks?
Can a wetscore be added?
Can pre-slitters be added on larger machines?
Can the fold plates all be set to deflect?
Can a microperf be performed?
Can various gutter trims be performed?
Can waste from trimming be removed properly?
Can multiple-up work be performed with slitting?
Can edge trimming be performed in the 2nd or 3rd stations?

Automate and Innovate

It is great to have automated equipment, but can the automation alone provide the level of quality that is needed? The bindery has multiple processes that all must work together to provide a quality printed and finished product. Automated products cannot automatically adapt to some functions like registration changes of sheets during imaging or printing, paper and ink stretch, and operator errors. Variances in the guillotine cutting process, paper quality, grain changes, etc. also can have an effect.

It can be difficult to repeat the same job time after time if one of the processes before folding can affect the consistency of the paper to be folded.

You must provide more than just automation to provide quality. You must provide information when you automate. An operator must know how to make a fold square, or score paper, or perforate, to name just some of the information needed for the highest quality and productivity from the folder.

Automated equipment should inform the operator as to how to load the paper, how to orient the paper for the proper fold, and more. Automated products that fail to inform the operator of the basics will frustrate the operator and cause MORE set-up time.

Mark Pellman is the director of sales and marketing for BAUM. BAUM has a line of floor-model folders featuring automation and information. The ifold is an industrial touch-screen computer that is mounted to new Baum ifold-compatible floor model folders. ifold provides information right at the machine 24/7 for all operators of all skill levels. AutoSet was developed by BAUM to provide a more advanced setup capability for the operator through automation. AutoSet combines all of the features of ifold and then goes further by adding automation to the folding process, teaching the operator how to setup, operate, monitor production, and maintain the folder. For more information, contact the Baum Sales Office at (800) 543-6107 or visit www.baumfolder.com.

JDF-based Print Production Workflow

August 21, 2007

by: James J. Mauro, Prinect Product Manager, Heidelberg USA, Inc.

Today’s aggressive printing environment is a by-product of fierce competition (from home and abroad); demanding customers, shorter turnaround times and runlengths; mergers and acquisitions; and increasing costs, all of which result in diminishing profit margins for printers. In many cases, the only way to compensate for low profit margins is to find more efficient methods of production. To this point, efficiency and automation based on JDF (Job Definition Format) have been the main topics in most trade events since drupa 2000.

The History of Data Exchange

The printing industry has invented and adopted “standard” formats since the beginning of modern workflow (mid-80’s). In those days it was nearly impossible to exchange page or image data between pagination systems (now called workflow systems) supplied by different vendors. The only way to achieve a harmonious workflow was to invest in a proprietary system. Proprietary was not only good, but it was the only way to achieve production.

With the Apple Macintosh computer came easy-to-use and (then) unsophisticated applications like QuarkXpress and Photoshop. This wave of new technology changed the graphic arts and printing industry on par with the invention of the Gutenberg printing machine and the Linotype machine. All of a sudden there were inexpensive computers, applications, and operators who could produce nearly the same high quality work as their more expensive counterparts. With this evolution came the need for ability to exchange image data between systems and as a result the industry invented image formats like TIFF (Tagged Image File Format) and DDES (Digital Data Exchange Standard). This seemed to work to some extent, but more was needed. Soon Adobe graced the industry with PDF, which was originally developed for the protection and sharing of simple documents. The printing industry caught wind of PDF and realized that it might be a useful format for handling otherwise huge page files. The rest is history. Or is it?

The Birth of JDF

The industry needed more than simply the ability to exchange image and page data. Printing presses became capable of remote ink control, meaning that a properly supplied file enabled the presetting of the ink fountains using digital data acquired from prepress. It was apparent that prepress systems of any kind would have to generate a file that could be delivered to printing presses that had this capability. In response, Adobe, Agfa, Heidelberg, and MAN Roland (known as the founding members of the CIP3/4 organization) developed the Print Production Format (PPF) for the automatic presetting of ink keys based on the same data used by the prepress RIP to generate film (later plates). This development was handed over to an independent organization which became the CIP3 Organization, which is why many people refer to a PPF as a “CIP3 file.” Since then, virtually every prepress RIP has the ability to generate a PPF. You would be hard-pressed to find a press with remote ink control that is incapable of accepting this file. But presetting inking systems was not enough for the fast moving train. The PPF was then extended to include preset data for many finishing systems. However, even with all the presetting capability that was becoming available, our industry still lacked the automated production of the sort found in many other industries. The next step toward workflow automation was realized with the Adobe Portable Job Ticket Format (PJFT) – workflows were automated using hot folders. But there was still no real integration with management systems.

There was still much room to expand and so the four founding members of the CIP3 Organization met again and embarked on the concept and development of a common language that could be used for integration and automation. The foundation for this language was XML (Extensible Mark-up Language). It was readily available and easy to work with so it was a no-brainer. JDF, the Job Definition Format, was born and was handed over to the CIP3 Organization, which morphed into the CIP4 Organization. As a result, we have JDF to preset, control, and record workflow, and JMF, the Job Messaging Format, which facilitates data collection through the direct integration of production systems. Thats the short story.

Since it was first announced at Drupa 2000, JDF is finally starting to gain some momentum and industry-wide acceptance. The current CIP4 roster includes over 330 members, which points to a growing interest and more importantly, a broad recognition of JDF by the printing community. The increasing deployment of JDF-based and/or enabled production workflows (there is a difference), as well as Management Systems, gives rise to the question as to where JDF is controlled in the production workflow. The proper deployment and integration of a JDF-based business and production environment promises to deliver a high level of automation, more efficient production, and more accurate cost analysis, all leading to more streamlined operations.

Workflow without JDF

Typically, Print Management Information Systems (MIS) are the systems to which all production activity is reported and by which the printer’s business is managed and controlled. The MIS essentially has been the starting, central, and end point in the business and production workflow. However, JDF-based workflow systems present the potential of shifting at least the production aspect entirely to the workflow, or the component which is sometimes referred to as the JDF store (where it belongs). Without the Job Definition Format, a typical production workflow would likely proceed as follows:

Jobs are estimated using the appropriate module of a Print Management System. As a result, a job ticket is produced (printed) and distributed through the shop, with operators logging their time and material usage through a shop floor data collection terminal which is part of, and connected to the MIS. In some cases, production machines are connected directly to the MIS providing more accurate machine production data collection (running speeds, printed sheets, etc.). At the end of production, all of the collected information is organized and used by the MIS to analyze production costs and efficiencies. In addition, other relevant information is used for payroll, warehousing, and other management, accounting, and operating activities of the shop. The main ingredient that is missing in this workflow model is not data collection or job distribution, but logical control of production. This is one area of efficiency where the use of JDF really proves valuable and demonstrates the need for us to rethink the way workflow will be structured in the future.

Using an MIS-centric workflow, all production transactions are typically (not always) processed manually through the MIS. There is little control as to when a job can be released from one stage of production to the next, except when operator A delivers the job jacket to operator B. This process can lead to the possibility of redundant data entry and also increases the potential of operator error, which can lead to honest, yet costly mistakes. The use of electronic JDF job tickets greatly reduces this likelihood but in a MIS-centered still does not address processing sequence-related issues. This is due to the fact that there is not a single information/production flow, but rather two paths: a MIS path (management and data collection) and a separate production path (moving the job bag from one production stage to the next).

Workflow with JDF

A production-centric JDF workflow offers a completely new logic in production automation, efficiency, visibility, control, and reliability. The JDF-centric production workflow system will validate the incoming JDF and control distribution throughout all stages of production.

A JDF-based production workflow places the production system at the center of the workflow and all other workflow components are essentially satellites, including the MIS, prepress, press, etc. This is a stark variation from the MIS-centric workflow in which, as previously described, the MIS is at the center production. In the JDF-centric Production Workflow, the MIS plays a critical role as it is the stage that the JDF is initiated and also is the receiver of all production data (via) for post-production analysis, accounting, etc. However, in this model the production data is not delivered directly to the MIS from production systems, but rather through the central JDF Workflow System, or JDF Server. As mentioned, it is the task of the JDF production workflow to accept and validate incoming JDF’s from the MIS, manage the distribution of the JDF (spawning and merging), collect JMF messages from integrated production systems, and deliver this information to the MIS for processing and analysis.

A JDF Workflow-based system presents a radical change in workflow philosophy and may be realized in the following scenario:

A job is estimated using the appropriate module of the JDF-enabled Print Management System. An electronic JDF job ticket is produced and delivered to the JDF Production Workflow system. The JDF is validated and forwarded to the prepress workflow for automated processing. JMF status messages are delivered to the central JDF workflow system upon completion of specific operations, and only when these operations are complete (i.e., proofing and plate-making) will the JDF be “released” and forwarded to the next stage of production, printing for example. At the press, the press operator loads the JDF job ticket through the press console, and the data included in the electronic JDF job ticket is used to preset the press with the manufacturing specifications as described originally in the MIS, as well as the ink presetting as derived from the prepress RIP (traditionally this has been achieved through the use of PPF – Print Production Format). As the press is running, it continuously reports production data (operator, job number, job name, sheet counter, running speed, production time, etc.) via JMF messages, through the JDF workflow system and ultimately to the MIS, enabling up-to-date production visibility. It is a highly transparent process and the same sequence continues through all stages of production, with the JDF workflow system providing live production information to the MIS. Operators using equipment that is networked and JDF-“aware” can log into the system through the machine interface, providing the benefit of fewer shop floor data collection terminals as well as highly accurate capture of production data (machine time, operator time, materials, etc.). In the same way, we can expect modern, JDF-based bindery equipment to not only accept machine presetting data but more importantly, highly accurate production data, fed to the production workflow via JDF. Operators using older equipment or equipment that is not JDF-compliant would use JDF-based shop floor data collection terminals, much as they are used today.

The main difference in this workflow is that production data collection (either by direct connection or by user terminals) is not a function or component of the MIS, but rather a JDF component/module of the centralized JDF workflow system, and that the MIS is not at the center stage of production. With a true JDF-based workflow, the production information path and the management information path are one in the same. This ultimately will lead to a more efficient and less error-prone workflow. Even the most conscientious employees make mistakes. It is human nature. Depending on when and where the error is detected directly affects the cost to correct even the simplest of mishaps. The worst place for errors to occur is in finishing. Incorrect cutting, folding, or stitching based on bad information or careless mistakes can result in costly reprinting. Any mistakes that can be avoided will result in a more profitable operation and enable a printer to increase equipment utilization. Given capacity, more jobs can be taken in-house without additional investment in labor or capital equipment.

Such a workflow would dictate that the Management Information System does, as its name implies, manage information, and empower the JDF production workflow to manage and control the production workflow. The MIS should manage non-production business activities, including warehousing, payroll, deliveries, invoicing, etc. The production workflow should manage the actual production of the job from initial processing though printing and finishing. The two systems must work together, which makes compliance to the CIP4-JDF specification an absolute necessity for efficient production and print job/shop management and performance.

It should be noted that at this time the current version of JDF is 1.3 and the CIP4-JDF specification (ICS – Interoperability Conformance Specification) for finishing systems has not yet been completed. Many enhancements to JDF, including finishing specifications are forthcoming in JDF 1.4, which is expected in the Fall of 2007. It is important that printers investing in new equipment (workflow and otherwise) consult with their vendors and clearly identify their JDF product status and roadmap. Also ensure that the systems being considered are either already JDF-based, or have a path to CIP-4 JDF compliance.

Our industry now has the means to bring efficient and streamlined automation to print production, from MIS to prepress to press and to the bindery.

Heidelberg’s Prinect family of integrated workflow management solutions provides maximum productivity and transparency throughout the workflow. With Prinect, Heidelberg is the only industry supplier to provide a totally integrated workflow from a single source. To learn more, visit www.heidelberg.com.

Automating Your Bindery: What Equipment Do You Need to Drive Your 2007 Business Goals?

November 21, 2006

by: Nancy Lowther

“The first red flag in any manufacturing operation indicating there is a need to automate is when there is a domino effect occurring, where one operation is affecting another in a negative way – a bottleneck, a slow process that impedes the next” says Douglas Kelly, editor and chief of APICS magazine and director of industry content.

As well as identifying bottlenecks, there are questions to address that will help binderies when conducting resource planning.

What jobs are your sales personnel turning away or losing? Is it because production cannot meet the job deadline (your bindery productivity is too low)?
What jobs are you accepting and then farming out?
How have current customers’ needs and products changed? What new customers have located in your area?
What automation (new bindery equipment) has your competitors incorporated and do you have comparable equipment?

Kelly also suggests that “a good consultant can come in and scrutinize your process and workflow. They question such things as legacy actions – doing things a certain way because ‘Bob’ used to do it that way.”

Bindery Automation in Action

Anna Massey, sales and marketing manager at Plastikoil, says that plastic spiral mechanical binding has been construed as labor intensive for a long time. How the operator held the crimping pliers and the experience and speed of the operator affected the output. In the past, coil inserters had belt-driven inserters – dozens of these lined up and dozens of operators. Consequently, productivity suffered. “So for me, automation means hands-off and higher productivity. It provides consistency. Automating this process with the Plastikoil Interline system means the operator places pre-punched books in place and the machine does the rest. It forms the coil, cuts it to length, drives it through the punch holes, and simultaneously cuts and crimps both ends,” states Massey.

Other than consistency, “There’s a 50 percent savings in material costs,” continues Massey. With this system, users can purchase spools of raw material and produce the exact length of coil needed for each job, versus making-do with pre-formed lengths from an outside supplier. These spools are half the cost of the equivalent amount of pre-made coils and there also is less waste (from cutting down pre-made coil to the exact size needed). Additionally, this system reduces the number of operators required because of the automatic inserters. “Companies may suddenly have a huge job available to them and this is often the catalyst for automating.”

When considering automating Massey says, “companies really should do their homework and research what is available.” Ask manufacturers for references – but not just the standard prepared list of names. Ask for the customer who has most recently installed the equipment. Ask that customer what made them choose it. Go to trade shows and see equipment in operation. Meet the sales reps and the service staff and see if you feel comfortable with them, if you feel they are credible, and if they can help you with your decision-making process without skewing the facts. Do they truly understand your business and the industry?

Mark Rasch, vice president of marketing at Rasch Graphics, a trade bindery in Houston, Texas, says “technology has changed and we changed with it. Today we’re faster. One of the beliefs we have is if we can replace people with machines, we do because the machine is there every day, on time, and if well maintained, is never sick.” Rasch Graphics automated by purchasing a Polar guillotine cutter since its old machine “just cut paper.. Now the company only requires one operator versus three because the cutter output has doubled. A photoelectric eye automatically brings the pallet of stock up to feed the cutter. A scale keeps the lifts in specific sheet counts and also jogs them. After the stock is cut, it is automatically jogged and packed perfectly on a skid.

The company’s old plastic coil equipment with its cloth belts and manual insertion of the coil produced 80 books per hour. Over a six month period, Rasch did an in-depth investigation of all the plastic coil equipment that was available. Now its new Plastikoil Concept QS2 system spins the coil through the book, forms it in-line, and produces 1,000 to 1,200 books per hour. For this company, automation was driven by its reputation for high quality work. When Rasch bid on several large projects and won, it needed to automate the bindery in order to deliver on time. “Automation means quicker turnaround, a lower price for the customer, and not only keeping up with the competition, but being a leader.”

“Automation means different things to different people. It can be anything from a fully automated JDF workflow to the automation of a single piece of equipment, an island of automation,” says Mark Hunt, director of marketing at Standard Finishing Systems. “To us it’s not an ‘all or nothing’ proposition. There are steps depending on how deeply and quickly a company wants to go.” With the margin and pricing pressure in the printing industry, companies are looking for ways to drive the labor cost down and stay profitably engaged. With shorter runs and thus more job set-ups per day, this means automated equipment. Related to that is the need to not compromise the quality of the final product, to maintain reliability, and thus make customers happier.

Another way a company can decide what equipment to automate is to analyze the lifecycle management (maintenance) reports for each piece of equipment. If it has been well maintained and has had few or no break-downs, then Hunt says to look at how much product is coming off it and check to see if this matches the specs in the manual. What is the actual spoilage, true productivity from that equipment versus any perceptions that exist? There was not a lot of measurement in the past. “The Horizon i2i bindery control system supplies visibility by capturing job statistics, actual productivity, and jams that occurred so these measurements can be compiled and then analyzed. And a CSR then can go into the system to see how much of the job is complete and if there are any problems in order to answer customer questions instantly. Binderies now need to automate just as prepress, press, and distribution have automated.”

Acculink Inc. is primarily a digital company with some offset, a bindery and a mail shop. President Tom O’Brien says that it is difficult finding skilled employees, so automating with devices that aid in set-up and changeover are necessary. “At Graph Expo, we plan to particularly spend a lot of time looking at all the bindery equipment.” Recently, the bindery purchased an M2 booklet maker and an Easy Crease machine from Standard Finishing in order to increase its productivity. “Productivity is one of the best indicators of how a company is doing and the sales per employee is how we measure that. In the last five years, there’s been little industry growth, resulting in fewer printing companies. But last year we grew 15 percent and are on track for seven more percent this year,” states O’Brien. Companies that want to survive will automate so they can deliver better than average quality and do it quickly.

As well as doing a ROI when planning on purchasing more automated equipment, the management at Acculink Inc. looks to see if there are specific customers with specific products, and if this is a sustainable market. The company checks to see if its operators have the skill set required and if the equipment can be serviced in-house and if not, what services are available outside. Acculink studies how to improve what it does so as to position itself as the vendor of choice.

At Globus Printing, the company has been actively automating its bindery. Globus added a STI hopper loader on its Kolbus perfect binder. This takes a lift from the press and places it on a conveyor, automatically feeding the perfect binder. Prior to this automation, the company had four to five people loading the pockets. Now only one person is required. Denny Schmiesing, president, says that “when this was done manually, it was easy to pick-up a signature and put it in the wrong pocket.”

Last year the company purchased a Baum folder and it has just added a Baum ifold, which is a set-up tool. The operator clicks on “fold” and a list of steps to set-up the machine appears on screen. “Recently an operator on night shift started running the folder that had been set-up on day shift but there was a problem. He checked on the ifold screen and found that the job hadn’t been set-up correctly and was then able to fix the problem and continue the job,” says Schmiesing.

By automating, the quality at Globus Printing has risen and the company better competes with other companies. Schmiesing summarizes by saying, “Automation is a necessity. If a company hasn’t automated, it probably isn’t there anymore.”

Nancy Lowther is owner of Lowther Training and Development and can be reached at (416) 282-1890.

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