Cutting

Labor Reduction Technologies: New Software Solution for Guillotine Cutting

December 9, 2016

by Zeenath Haniff, Farheap Solutions

Using touchscreen technology, Scissor Hands software allows for reduction in errors and improved function.

It is commonly believed that bottlenecks in print production most often occur in the bindery. But, to reach the finish line, let’s look back at the start. While the finishing may be the most time-consuming stage, what other factors consequently affect the time it takes for print jobs to reach the bindery where the cutter operator is forced to make up for any lost time?

Many print service providers invest in the latest prepress and cutting machines to produce high-quality products at record speeds, yet fail to consider how to pass the baton to finishing. Even the most advanced equipment requires a skilled journeyman who can fluidly manage the production timeline. Implementing an efficient workflow between prepress and press can vastly improve post-press production times and quality of the finished product.

Bottlenecks eliminated at OvernightPrints.com

As the founder of OvernightPrints.com, a leading e-commerce printer of business cards, postcards, brochures and other printed materials, Brett Heap originally founded Opensoft Inc. to directly solve his own printing issues. The drive to maximize the efficiency of guillotine cutters at his production facilities in the US and Germany led to development of software that would improve function and reduce errors.

“In the beginning, (Overnight Prints) wasted a lot of paper. Run sheets would have empty positions because they needed to get printed and out the door,” said Paul Barnum, COO, OvernightPrints.com. “Brett (Heap) has always driven everything toward eliminating waste and reducing the cost.”

Under Heap’s direction, the production facility programmed prerecorded cutting routines into several Itotech guillotine cutters. Manual adjustments by cutter operators, however, would inadvertently change the cut courses and naming conventions of the cutting routines, resulting in inaccurate cuts.

To eliminate errors and reduce waste, Heap moved to connect the machines and automate the process. After consulting the manufacturer, the machines were rewired to enable broadcast signals between them. Engineers then were hired to write programs for the cutters, and that software would eventually become Scissor Hands.

“We had to reverse engineer the signaling of the cutters to figure out how to tell the machine the next cutting course,” Barnum explained.

Software adds cutting efficiency

Scissor Hands demonstrates how a single software solution can effectively reduce production and labor costs on gang runs. Created to optimize guillotine cutting and maximize overall print production, the cutting automation software was conceptualized for internal use in 2012 at Overnight Prints, but the technology had implications for the print industry as a whole.

The enhanced JDF automation works by creating efficient cut sequencing based on a run’s prepress JDF data, sheet count, substrate coatings and packaging intent. Barcodes are added to the press sheet from which the software reads the job. Once scanned, the software displays the live image of the job, calculates the most efficient sequence of cuts and loads that sequence into the cutting machine in fractions of seconds.

Unlike previous methods, the automatic job loader also saves a tremendous amount of time by eliminating the need for the operator to search for a specific cutting routine. Instead of storing hundreds of cutting courses, Scissor Hands customizes each print job.

“Every time a new press sheet is built, the information goes to the machine, and it’s specific to that job. We could save the routine, but we don’t need to anymore because it acts like a new job every time,” said Barnum.

The software adds artificial intelligence (AI) to guillotine cutters. These AI-created cut programs share cuts across lifts to reduce the total number of cuts needed to finish an entire run. Shorter, smarter cut programs reduce blade wear and extend the longevity of the cutting equipment, ultimately saving time and money on maintenance and upkeep.

Job runs simplified for operators

Labor costs are another demonstrable cost savings for production facilities that implement the print cutting automation into their workflow. While some manufacturers of similar systems display cut measurements as line drawings, Scissor Hands shows the actual product image onscreen with step-by-step animation of cutting each step from start to finish without having to calculate, enter dimensions or adjust by numbers or visual observation. Operators just follow the presentation for how to load and rotate the lift.

The efficiency of the provided algorithm, combined with guided animation, allow for entry-level labor to complete print jobs, which significantly reduces the need for experienced journeyman. Additionally, operator training time can be condensed.

Some of the most experienced cutters at Overnight Prints shared that the software would save 20 minutes of every hour in cutting time alone. Operators no longer need to waste significant time calculating, doing decimal conversions or planning cut courses before they begin cutting.

An integrated MIS system provides real-time reporting. It can track the name of the employee completing the print job, start and stop times, blade drops and other relevant data.

The Scissor Hands technology was on display at the recent GRAPH EXPO 16 in Orlando, Florida.

Awarded a 2015 Must See ‘Ems Award, Scissor Hands was named a leading innovation in cutting edge automation by a panel of industry experts at GRAPH EXPO 15.

Zeenath Haniff is the content writer for Farheap Solutions, Las Vegas, Nevada. Scissor Hands uses artificial intelligence to augment a cutter’s behavior. The cloud-based auxiliary system only requires the installation of a mounted touchscreen, barcode scanner and model-specific connector to enjoy the benefits of newer imposition software on older equipment that are not fully computerized. Scissor Hands can work with any cutter that has a programmable back gauge. For more information, visit www.scissorhands.net.

Q&A: Cutting Difficult Substrates

September 4, 2015

by Jen Clark, PostPress

Bruce Peterson, president of Colter & Peterson, Paterson, New Jersey, says using proper cutting techniques and clamping pressure is essential when cutting difficult substrates.

Basic preventative maintenance can go a long way toward keeping paper cutters working properly, especially when cutting difficult substrates. Regular maintenance can reduce production issues, said Bruce Peterson, president of Colter & Peterson, Paterson, New Jersey. “A machine always needs to be lubricated, and a paper cutter should have its oil and filters changed every 2,000 hours of use,” he said. “If the oil isn’t changed, it loses viscosity and begins to break down. That will lead to other issues.”

Regardless of the machine’s age, keeping it and the area around it clean also is important, not only to preserve the machine’s peak performance, but for operator safety as well. Oil on the floor, for example, can lead to injuries. “If there is dirt nearby, it should be cleaned up so it doesn’t mess with the machine. If an operator hears something that doesn’t sound right, that’s the signal to give us a call,” Peterson said. “It’s always better to catch something sooner rather than waiting until it’s too late.”

PostPress asked Peterson about cutting difficult substrates and the effects they can have on both blades and machines.

What should be kept in mind when cutting difficult substrates, such as plastic sheets, shiny UV coated sheets and sheets with embossing, etc.?

It depends on what kind of substrate it is, but using proper cutting techniques always is a good idea. Having the right clamping pressure is essential. The softer the paper is, the more pressure is needed, and it’s the opposite with harder paper. Never adjusting the clamp pressure eventually leads to cutting problems. Another thing to keep in mind is every printed sheet has a guide and gripper edge. It needs to be inserted into the machine properly with the correct pressure and program.

What types of blades should be used?

The majority of our customers who cut paper use blades made of 18-percent tungsten steel. It’s a harder steel and less susceptible to developing problems. By properly caring for it, this blade is capable of 60 to 80 hours of cutting time before needing to be replaced. If customers are cutting chipboard, I would recommend standard steel knives, which are a lower grade.

What effect does difficult substrates have on blades? What can be done so that the cutting blades last longer?

It varies. Tungsten steel blades work very well on fine, high-quality paper. It’s perfect for 70-80lb, 8-10-12pt board, coated stock and will last for 60-80 hours before it is gets dull and needs to be replaced. If operators notice that the blade is causing nicks in the paper, they should stop using it because it needs to be changed.

More people are switching to blades made from tungsten carbide, which is an even harder grade of metal than the ones with tungsten steel. These blades are more impervious to wear and tear and they could last five to 10 times longer and with less down time, depending on what type of material they are cutting, how often and other factors. The tradeoff is they cost three to five times more, they can be more brittle and susceptible and they don’t work well with glue. If you bind books, these are not the kind of blades you want.

The people who cut chipboard should stick with standard steel knives. Chipboard has a lot of foreign material inside, such as crushed rocks, stones and staples, that causes gradual wear and tear. If an operation is cutting different substrates, chipboard should be the last thing its operators cut for the day, just in case a problem develops that causes down time for the machine.

How often should blades get changed?

The stresses a dull blade places on a paper cutter are astronomical. It smashes material instead of cutting. It is an easy problem to solve – just keep the blade sharp. There are five early warning signs of a dull knife, including

a rough or chipped cutting edge;
a banging sound when cutting through a pile;
the cut material sticks together;
the cut edge is ridged or turned down; and
inaccuracies in cutting, like overcuts and undercuts.

All machines today have cut counters. Operators can see how many cuts they are getting out of a blade. Clients may find that if they change the blade every 40 hours or approximately every 4,000 cuts, they are changing the blade in advance of it getting very dull, before it damages material or the machine.

Bruce Peterson is president of Colter & Peterson. As an independent distributor of paper cutters and paper handling equipment since 1932, Colter & Peterson has serviced, repaired and rebuilt all types of paper cutters from 20″ to 112″ in size, including Harris-Seybold, Dexter-Lawson, Polar, Wohlenberg, Challenge, Schneider, Prism and Saber. For more information, visit www.colterpeterson.com.

Troubleshooting Common Cutting Problems

November 21, 2012

by: Jen Clark

Dull blades cause cutting problems, and so do poor maintenance, lack of proper operator training and insufficient knowledge of safety procedures. Bruce Peterson knows this. The self-proclaimed “Cutter Doctor,” who also happens to be president and CEO of Colter & Peterson, Inc., Paterson, NJ, knows a thing or two about paper cutters. He said most cutter problems fall into one of three areas: dull blades; dirty, run-down and poorly maintained equipment; and poor operator training coupled with a lack of safety awareness. “Most of these are maintenance/management related issues,” he said. “If you pay attention to your machine, you’ll hear or see small problems and you can alert a technician to them before they get to be big issues.”

Peterson says “Cutter Common Sense” can go a long way to keeping an operation running smoothly. These are things he has learned over his nearly 40 years in the paper cutting industry.

Regular Maintenance Can Reduce Production Issues

Neglecting the blades on paper cutters can damage product and lead to costly reruns. “The stresses a dull blade places on a paper cutter are astronomical,” Peterson said. “It smashes material instead of cutting. It is an easy problem to solve – just keep the blade sharp.” The five early warning signs of a dull knife include a rough or chipped cutting edge; a banging sound when cutting through a pile; the cut material sticks together; the cut edge is ridged or turned down; and inaccuracies in cutting, like overcuts and undercuts.

Peterson recommends changing blades every 40 hours of cutting. “When I go back (to a client) a year after installing a new blade and the edge is more like a round pipe, I know they aren’t being sharpened properly. All machines today have cut counters. You can see how many cuts you get out of a blade. Clients may find if they change the blade every 40 hours or approximately every 4,000 cuts, they are changing the blade in advance of it getting very dull, before it damages material or the machine.”

Basic lubrication keeps a cutting machine running smoothly. Much like a car, the machine’s oil and filters should be changed every 2,000 hours of use, he said. “People often don’t pick up an oil can and lubricate according to schedule. If you don’t change the oil, it loses viscosity and breaks down. The machine won’t work properly.”

Regardless of the machine’s age, keeping it and the area around it clean also is important, Peterson said. Oil on the floor can lead to costly operator injuries. If there’s dirt on the machine, clean it up. “It’s about taking pride in your operation. Do a visual inspection every couple of weeks,” he suggested. “If you hear something that doesn’t sound right, that’s the time to say something. Don’t wait until a bearing shatters and breaks something else.”

Operator training is another area of concern for Peterson. In the past, cutter operators were craftsmen who spent all of their time at one machine. They knew the nuances of their machine and when things weren’t working right. Over the years, “the level of training has been reduced,” he said. “There’s less of a connection to the machine. Thirty years ago, operators would consider it ‘their machine…their baby.’ They’d take care of it, and they knew when something wasn’t right. Now, operators have a lower degree of training, are moved from machine to machine and rarely handle maintenance. It’s a different philosophy that drives down the ability of the machine to perform.”

Proper Technique Increases Quality, Safety

Operators also should use proper cutting techniques. Depending on the type of paper being cut, operators should set the machine to the right clamping pressure. “But there’s a paradox,” Peterson said. “The softer the paper is the more clamp pressure you need; the harder the paper, the less clamp pressure is required. Some people never adjust clamp pressure and that leads to cutting issues. In addition, every printed sheet has a guide and gripper edge,” he said. “You have to insert it into the machine properly, use the correct pressure and program the machine properly.”

Safety is another area of concern. The guillotine cutters of today are safer than in the past. Non-repeat devices, dual two-hand/hold knife actuation and infrared safety light barriers help ensure the powerful blade cuts nothing but the intended material, he said. Workplace safety is a crucial concern, since injuries can cause significant losses in both physical and financial terms.

When it comes to safety, there are two distinct areas of concern: avoiding Cumulative Trauma Disorders (CTDs) and avoiding injuries that occur while operating the cutter. Studies have shown operators spend only 1/3 of their time cutting, while their remaining work hours are devoted to moving material. To avoid or reduce the occurrence of CTDs, Peterson recommends the following: combining modern technology, equipment and work processes to reduce strain on operators; analyzing the cutting operation to identify areas needing improvement; automating workflow as much as possible; eliminating risk factors; and finding ways to make the overall cutting operation more ergonomic.

While safety has come a long way, injuries still happen. “Clamps have been responsible for most of the accidents on paper cutters, but they are not the only culprits,” he said. “The action of paper cutting has always been, and will always be, a safety concern.”

Peterson offered seven tips for reducing cutter operation-related injuries:

Every paper cutter installation should conform to the latest industry standards.
When possible, install an effective cut line clamp system to show where the knife is going to cut without lowering the clamp.
Use push-outs or “ream ejects” in the cutting program.
Ensure the cutter has a two hand start/two hand hold system with an anti-tie down circuit.
Always use a jogging block when placing hands under the clamp to side jog material.
Check that the cutter has sufficient back up (redundancy) to ensure safety will be maintained if something goes wrong.
Ensure proper installation of safety bolts and/or latches to back up the clutch/brake (or hydraulic ram) and prevent the knife from making an unintended cycle.

Fixing these common cutter issues before they become problems should be part of normal operational policies. “Companies should perform regular maintenance, put more time and effort into operator training and set up a plan to change blades depending on the usage of the machine,” he said. “Every plant manager should study the risk and costs of operator injury when deciding between operating an older machine and upgrading to a newer one together with paper handling equipment.”

Equipment Suppliers Offer Expert Advice

Equipment suppliers, Peterson said, can be a great resource for advice. “They take a consultative approach in applying solutions and often prove to be the best source of advice on upgrading cutting operations.”

At Colter & Peterson, giving advice is a cornerstone of its business. About a year ago, Peterson said the idea for the “Cutter Doctor” came up. “It was a marketing idea – a way to get people to ask questions and get answers to the problems they may have.” Through a new website, www.cutterdoctor.com, Peterson and a variety of individuals with expertise in specific areas of paper cutting, paper handling and the printing industry offer tips about improving operations.

Some manufacturers require payment to ask questions, he said. “One of the first things they say when you call is ‘What’s your name and credit card number?’. We’re trying as best as we can to answer questions about paper cutters. We’re comfortable talking about any kind of paper cutter that a customer may have. It’s what we know. We try to help.”

Since 1932, Colter & Peterson has serviced, repaired and rebuilt all types of paper cutters from 20″ to 112″ in size, including Harris-Seybold, Dexter-Lawson, Polar, Wohlenberg, Challenge, Schneider, Prism and Saber. The company, known as Hagman & Peterson in its early days, operates out of multiple facilities in three states. In addition to selling its own Prism and Saber paper cutters, Colter & Peterson also supplies paper handling equipment, parts, service, retrofit computers and safety upgrades for most makes and models of paper cutters. For more information, visit www.cutterdoctor.com.

New Technologies in Cutting and Trimming

August 21, 2010

by: Amy Bauer

Delivering high-quality results and offering the best value to customers in print project finishing are the goals underlying a range of innovations for printers and binders. These new cutting and trimming technologies are streamlining processes and reducing labor costs. The fewer times an operator must intervene during a job, the greater the production speeds and the lower the chance for errors. Here are some of the industry’s latest developments.

Hands-Free Automation

Smaller, on demand book orders require a nimble staff and machinery to fulfill the requests quickly and cost-effectively. The Challenge Machinery Company’s CMT series of on demand book trimmers offers fully automated book-of-one production trimming with the new Txe and TxL control systems. Barcodes printed on the precut book blocks send the job dimensions to the trimmer for complete automated set-up. This exclusive feature requires zero human intervention between books, no matter their size differences.

Standard Finishing Systems has designed its new Standard Horizon HT-80 automated three-knife trimmer to trim books of varying thicknesses, one after another, for on demand book production. The HT-80 can trim books off-line or operate in-line with several Standard Horizon perfect binders. It features the “intelligent automation” built into all Horizon post-press products. An intuitive, icon-based, 10.4″ color touch screen assists with automated setup, including the infeed, jogging, and knives. Up to 200 custom jobs can be stored in memory, and the HT-80 is compatible with Horizon’s pXnet bindery management system.

Push-button programming also is a feature of the Baumcut 31.5 and Baumcut 26.4 programmable cutters, from Baumfolder Corporation, which offer ease of operation and minimal maintenance. The heavy-duty, fully hydraulic cutters can store up to 99 programs with 6,464 cut steps, with a large central liquid crystal display indicating the data in the selected language. Safety features include infrared safety beams; two-hand, timed cut release; and covered rear table. A built-in table light and optical cutting line ensure precision.

Muller Martini’s Orbit three-knife trimmer boasts complete changeovers within three minutes with full automation and can process a wide range of book sizes without special kits. SmartPress technology provides constant, gentle pressure on the materials, allowing more time for evacuation of air for precise trimming. Individual servo control eliminates makeready on many functions and improves performance by separating drive line. The Orbit’s controlled transport system includes special belts and servo motors that lift the books and move them into position. Precise control of knives to stick contact reduces grinding costs.

Sizing up the Job

Accommodating jobs of all sizes can be a challenge, especially when a shop’s square footage is limited. New technology is addressing the varied requirements of wide-ranging print requests. Perfecta USA has introduced the 92 AWR (36″) paper cutter with automatic trim removal. The 92 AWR is tailored for smaller shops that have a large amount of printed jobs with gutters but do not have the available floor space that the larger machines require. The 92 AWR joins the list of automatic trim removal cutters from 45 to 88 inches available from Perfecta.

For the past couple of years, an 18 ½” paper cutter has been the standard for copy centers that work with 12×18″ paper stocks. But more manufacturers now are offering print engines that have a 13×19″ capability, which has created new challenges that 18 ½” cutters can’t handle, notes Matt Roth, vice president of Spiral Binding Co. “Spiral Binding Co. does not manufacture cutters, but we only sell the ‘best -in-class’,” Roth says, “including products from Challenge Machinery, Duplo USA, and MBM Corporation.”

Flexible Features

New innovations are improving the way paper cutters accommodate jobs. Heidelberg has introduced a new generation of POLAR high-performance cutters and cutter models in widths from 26″ to 69″. These machines offer an array of new options for cutting and paper handling, including swivel/tilt back gauge; down-holder in front of the knife to prevent mixing and shingling of multiple-ups; down-holder at back gauge, which holds down curly sheets; and Fix-o-Mat for correct alignment of irregular lifts. Autotrim provides automatic waste removal to increase productivity, and its air knife handles plastic sheets or static-loaded materials, while the AntiStick Knife prevents residual material from sticking.

Duplo USA Corporation also has addressed varied needs with its 800PA Hydraulic Cutter, which is designed to offer precision cutting for documents on a wide variety of paper stocks and weights. Its special low-friction surface aluminum alloy cutting bed requires no polish or waxing and won’t rust over the life of the cutter. It comes standard with an air-cushion table, allowing heavy paper stacks to be moved easily across the cutting bed. A color touch-screen control panel allows for ease of programming. Safety features include a large working area with side table, full light beam curtain, and dual-palm-cut buttons.

Multi-Tasking Machines

Printers and binders also are finding flexibility with machines that perform multiple tasks, sometimes even within a single step, thereby reducing the need for separate operations or outsourcing. Technifold’s Multi Tool originally was made to produce either guillotine-quality trimming or die-quality micro-perforating on any popular folding machine. It now can perform these two functions simultaneously, adding more flexibility in finishing single- or multiple-up jobs on the folder. A slight change to the construction of the perforating anvil allows the cutting and perforating operations to be conducted at the same time. The distance between cut and perforation can vary from ¼” up to 1 1/8″.

Rollem International also is focused on multitasking. The company has introduced its new 2D digital finishing system for multiple-up photo cards, postcards, greeting cards, and more. The two-directional system edge trims the press sheet in both directions, slits each card, and applies fine-quality score and cut-score. This method eliminates the need for guillotine cutting and additional labor as the cards are finished in one process. A folder can be added for complete automation from press sheet to finished product.

Clean Cuts

The condition of a book’s spine, or backbone, is among the first things customers notice, and a strong, unmarred backbone helps ensure a book’s longevity. Jorson & Carlson Company spent about a year of research and development in creating the Back Bone Buster, which eliminates backbone chips and tears. The Back Bone Buster is a unique side knife application for trimmers that pre-cuts the bind of the backbone prior to the side knife cut. The product works for both saddlestitched and perfect bound books and is ideal for any binder that cuts books ½” or less.

Industry innovation, as seen through these companies and their products, reaps rewards for printers and binders, who can use these tools to provide higher-quality printed materials more quickly and more affordably to customers.

Best Practices for Paper Cutter Knives

August 21, 2009

by: Woody Powers II, Jorson & Carlson

A knife supplier or servicing company with expertise in knife quality, knife handling and product application, as well as the know-how to install cutting knives properly, can provide useful best practices to improve cut quality and increase knife life. In most cases, implementing new procedures will increase quality and production time by eliminating costly knife change time.

Fundamental Questions for Cutting Jobs

When cutting products such as books, labels, and letterhead, it is paramount that operators abide by strict fundamentals to achieve optimum cuts and production. Questions to ask before making the first cut include the following:

Has the job been coordinated with prepress, press, and bindery to supply the most efficient layout for all involved? Are the right paper weight and paper size being used for the job? Too much trim can cause excess waste and deflection problems, like back bone chipping on a perfect bound book.
Is the correct equipment being used for the job? Is proper maintenance provided for the equipment per OEM recommendations?
Will the cutter, folder, stitcher, or perfect binder produce a product quality that is acceptable to your customer?
Does the operator have the knowledge needed (and the ability to engage that knowledge) for the job given to him?

Good housekeeping, proper job layout, good machinery, the right paper, and the correct cutting knives, ground by a professional knife grinding service, will provide a quality finished product.

Increasing Cut Quality

A full-time bindery with multiple shifts should be using inlaid knives manufactured with 18 percent tungsten alloy or – the ultimate in wear resistance – carbide. Both of these out-produce carbon steel cutting knives. Many people are confused by the term “18 percent tungsten” – it is not carbide, but rather an alloy steel with 18 percent tungsten mixture. The term “carbide” also is misrepresented and misunderstood. There are different grades of carbide. One of the best, most wear-resistant grades is MG28, an ultra-fine grain.

Using upgraded metallurgy maintains the desired cut quality for a longer production time. Never upgrade knife quality to improve cut quality. There are companies that sell coatings or offer to rebuild old knives; however, there are no substitutes for upgrading the metallurgy to improve longevity.

Proper Installation

Proper installation of cutting knives is very important in achieving longer lasting cut quality. Changing knives quickly will not improve quality. A job done right will improve quality and longevity, while also allowing distortion-free cuts.

When changing knives, never place a new knife on the cutter bed. This will ensure a knick-free knife is installed. Instead, always place the knife on a piece of chipboard or on a changing table with the cutting edge facing away. Using Kevlar gloves, clean the knives with a solvent to remove any oil, dirt, etc. Visually check the knife edge for imperfections. The same cleaning procedures must be applied to the cutting machine where the knives are mounted. With 3-knife trimmers, clean the holders where the knife is mounted. Remember that any surface upon which the knife is mounted becomes an extension of the cutting knife. Any paper, dust, or grease trapped between the knife and the machine can cause problems.

When installing guillotine knives as per OEM instructions, always back off the knife setting adjustments so the knife will not cut through the last sheet of paper. When tightening mounting bolts on larger knives, always start tightening from the middle out to the sides; smaller knives tighten from one side to the other side. Using this procedure nearly ensures that a bow will not be trapped in the knife, causing deflection in the cut and making it hard to seat the knife. Make the final knife adjustment in the cutter as needed – just enough to cut through the last sheet of paper.

When using cutting sticks, make sure the stick is properly seated in the stick channel. Cleaning this channel is very important in getting an even setting of the knife. If the channel is not clean, the blade will be damaged on the first penetration. Once the blade has been seated to the cutting stick, do not cycle the knife lower into the stick to get a cleaner cut. If needed, change the stick. If this needs to be addressed often, a blade change is needed.

Knife Grinding

When the knives are dull, send them to a qualified knife grinding service. Just as bindery equipment has evolved, so has grinding equipment and the techniques used to sharpen knives and remove burrs.

A grinding service that grinds the knives first, and then hones the knives by hand is using an older, outdated procedure. With this process, the degree of sharpness depends on the pressure exerted by and the steadiness of the person honing the knives. This will leave scratches, marks, and back bevels on the face of the knife, which can lead to knife deflection problems and product marking.

The new knife grinding technology incorporates state-of-the-art grinding equipment to grind and mechanically hone knives on the same machine. This guarantees burr removal and precise blade sharpness, ensuring consistent repetition from knife to knife.

With the help of the right vendors, implementing new procedures will increase quality and production time by eliminating costly knife change time. A few simple changes can help bindery owners improve quality without spending a lot of money by using the equipment on hand.

Woody Powers II has served as the president and owner of Jorson & Carlson since 1992, after beginning employment with the company in 1964. Jorson & Carlson is a third generation company, which began in 1917. It is a full service company specializing in precision grinding, with six locations in the United States. For more information, call (800) 656-7766 or email sales@jorsonandcarlson.com.

Cutting for Efficiency

November 21, 2008

by: Rob Kuehl, Director of Product Management, Heidelberg USA, Inc.

Don Quixote had Sancho Panza. Batman had Robin. Even the Lone Ranger had Tonto in his hour of need. Like these famous pairs, automated cutter workflows are more efficient and more productive with a partner – paper-handling peripherals.

Nothing is more fundamental to the success of a job than the efficient cutting of paper. Waste or inefficiency at the cutting stage invites error and injury, and can give rise to expensive bottlenecks. Sheetfed operations, in particular, can benefit from the use of labor-saving devices that reduce operator bending and lifting.

In the bindery’s cutting department, emphasis has shifted from conventional stand-alone guillotine cutters that traditionally have relied on manual loading, offloading, and adjustment to sophisticated systems. These new systems are designed to protect operators from injury, reduce the occurrence of bottlenecks, slash the time that printed materials must wait on the cutting table, and ease the transmission storage and repurposing of job-specific data throughout the plant.

New cutting solutions meet the need for:

Networkability
Ergonomic integrity
Minimal makeready
Simple maintenance
Operational readiness
Faster turnaround
Higher quality
Simplified processing of shorter runs
Fully automated production of large-volume jobs
Integrated materials handling
Complete cutting programs generated from prepress data, avoiding multiple input of complex job parameters.

The difference between stand-alone cutters and these more sophisticated systems is twofold. First, paper cutters have a limited ability to network with the rest of the plant. Second, a wide range of peripheral components are available to help ease the movement of paper to and from the cutter.

In any bindery department, the goal is to get material to and from the cutter quickly, easily, and reliably. Accordingly, the newest generations of high-speed cutters and cutting systems have been designed to be capable, productive, intelligent, user-friendly, ergonomically sensible, and infinitely configurable. However, equally important is the cutter workflow. An automated cutter workflow has two equally important parts: cutting and paper handling. Cutting is the main attraction, and it is performed by the cutter or diecutter itself. Paper handling is more easily overlooked. The default position of most bindery departments has been to rely on manual resources. Current options, however, are designed to standardize and automate as much of the grunt work as possible. Some of these paper-handling options include front- and rear-loading stacklifts, joggers, conveyors, and pile-turners.

It Takes Two

Both the cutter and paper-handling peripherals are necessary to achieve a fully automated system that maximizes the operator’s cutting time and the number of cuts delivered by the knife while also minimizing the volume of paper handled and the time and labor needed to handle it. The aim is not to eliminate the human element but to increase the utilization of both man and machine. Automated cutting and paper-handling systems can improve the workplace environment and promote the health and well-being of bindery employees. (See Figure 1.) Cutter peripherals promote better utilization and increase the efficiency of the high-speed cutter and cutter operator. Repetitive motions, including but not limited to bending and stooping, are responsible for many bindery injuries.

Automation can reduce:

Time lost to cumulative trauma disorders, including back injury and carpal tunnel syndrome
Accidents caused by operator fatigue
Workers’ compensation claims

Well-designed mechanical solutions also can yield production efficiencies and drive growth by:

Reducing shifts and overtime
Redeploying workers
Enabling fast turnaround
Eliminating backlogs
Taking on more jobs without increasing overhead

Additional benefits of automation include reductions in:

Product damage
Material waste
Production and shipping delays
Wasted floor space

Moving Toward Automation
While the bindery offers the biggest opportunity for realizing the benefits of streamlined materials handling, few printing company owners and managers see it as a means of reducing their manufacturing costs. Many hesitate to invest in post press upgrades because they dont consider the bindery a profit center and instead reserve the bulk of their capital investments for the pressroom and prepress department. The reality is, whether through benign neglect or ignorance of their costs, too many printing company executives treat cutting and paper handling as a necessary evil.

Cutting and paper handling are far from “top of mind” in all but the most highly industrialized printing plants – and sometimes not even there. Consequently, after a company installs a new press or piece of bindery equipment, jobs start piling up at the cutter because the bindery’s paper-handling solutions aren’t fast enough to keep up with the increased load. This is more likely to happen when people are considered the paper-handling “solutions.”

Given that the most expensive variable in any cutting operation is labor, replacing manual lifting and repetitive-motion tasks with streamlined mechanical solutions makes more sense today than ever. The task for vendors is to demonstrate how automating their customers’ manual practices can benefit employee health, safety, and morale, as well as throughput rates. Viewed in this way, the automation of manual practices can literally pay for itself.

Don’t overlook the gains that can be realized by reducing cutter operators’ stock lifting and handling

Laissez-faire Is Best

Virtually every sheet of material to be cut needs to be handled internally before and after it winds up on the cutting table. Depending on the application, paper might need to be lifted, jogged, aerated, turned, and repeatedly moved. If an operator has to do the bulk of the labor involved, he or she risks back injury, especially with large sheet sizes and heavy stock. In addition, the likelihood that errors will occur increases the more materials are moved around by hand.

The addition of automatic loaders and off loaders, stacklifts, in- and offline joggers, trim-removal and banding devices, sorting and inspection devices, electronic counting scales, pile-turners, robotic arms, conveyors, and buffering systems can significantly reduce turnaround times and reduce or eliminate operator fatigue and back-related problems. (See Figure 2.)

For example:

Automated transport systems can regulate the efficient loading of materials to the clamp opening, reducing labor and promoting high productivity.
Operators using a fixed or freestanding stacklift can raise loads to a convenient height for loading uncut sheets to the cutter or jogger, or for unloading finished sheets. (See Figure 3.)
Automatic in- or off-line joggers can reduce the time it takes an operator to jog the stock into proper alignment for cutting, which makes for better product quality especially for high-quality, long-run jobs. (See Figure 4.)
Automatic off loaders or palletizers can help increase throughput during cutting for large-volume applications.
Pile-turners can facilitate preloading, work-and-turn applications, skid manipulation and aerating, and they can boost throughput by reducing or eliminating misfeeds due to double or missed sheets.

All of these peripherals are designed to increase the efficiency and utilization of the cutter and to make work easier and safer for the operator because heavy lifting is minimized or no longer required. Finally, graphic touchscreens and other user-friendly features of advanced cutting systems enable binderies to enjoy the benefits of computer-enabled technologies without depending on bindery employees’ high-tech capabilities.

Leverage Your Human Resources

Take steps to transform your cutting department from a loss leader to a profit center by automating as much of your cutter workflow as possible. Don’t “cut off your nose to spite your face” by overlooking the gains that can be realized by reducing lifting and handling by operators who are responsible for moving heavy stock to the cutter.

Consider an integrated, high-speed cutting system with flexible, modular paper handling. Cutting operations should not be balanced on the backs of your bindery employees. Do them and yourself a favor by installing systems that will help you leverage your human resources to their best advantage.

Rob Kuehl has been with Heidelberg in Germany and the U.S. for over 24 years. He was the first U.S. citizen to complete Heidelberg’s first-class machinist’s apprenticeship and moved up through corporate Manufacturing, Engineering, Procurement, Research, and Development. He can be reached at rob.kuehl@heidelberg.com or (770) 419- 6636.

New Technologies in Cutting & Trimming

May 1, 2006

by: Dianna Brodine

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

Before the First Cut

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

Automated Cutting Technology

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

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

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

Small Scale Solutions

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

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

Focus on Safety

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

Unique Solutions

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

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

Start Off Sharp

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

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