Mechanical Binding

Q&A: Paper Punching

November 15, 2013

The Binding Edge

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

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

What factors can affect the quality of the paper punch?

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

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

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

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

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

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

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

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

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

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

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

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

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

Two Steps to Efficient Riveter Set-Up

August 21, 2013

by Ted Rumatz, Bensons International Systems

Q: Custom binder manufacturers have different methods to set up their riveters when they change to a different job. Some are very efficient, making adjustments to the riveter in a matter of a minute or two; and others spend quite a bit of time with trial and error on every adjustment made. Are there tips that can speed riveter set-up?

A: There are two main adjustments to be looked at: the registration table and the position of the anvils.

1. With the registration table adjustment, look to set the machine so the ring mechanism attaches to the case in the desired position. An adjustment in the registration table is required when the size of the case (capacity of the ring mechanism) or the desired position of the ring mechanism in the case changes. However, most manufacturers frequently are making the same range of binder sizes, so it may make sense to create templates of the common binders manufactured.

Set the template desired on the registration table and tighten down the stops once the template is in the correct position. Doing this will make the adjustment quick and easy.

2. The other common adjustment is the position of the anvils. When the capacity of the ring mechanism or the thickness of board and/or cover material changes, frequently the length of the rivet required must change as well. This is when the anvils will have to be adjusted by raising or lowering them to accommodate the length of the rivet.

To speed the process, mark a strip of sheet metal or aluminum with the different rivet lengths. Use this as an aid to make the adjustment to the proper position of the anvils. It’s a real timesaver.

Bensons International Systems, Inc. is part of a global company which operates on five continents, including Bensons USA in Woodland Park, NJ. It offers a very wide variety of ring mechanisms and a one-stop-shop concept for range of accessory-type products commonly used in loose leaf manufacturing, such as clip board clips, metal corners, adhesive pockets, magnets, adhesive hook tape, loop tape and a number of other products. For more information, call 800.221.1024 or visit www.bensonsusa.com.

Mechanical Binding Reacts to Changes in the Market

November 21, 2011

by Staff

The demand for short runs and quick turnarounds has impacted every type of binding process, from saddlestitching to perfect binding to mechanical binding. For this Q&A, The Binding Edge contacted mechanical binding experts Gateway Bookbinding Systems, Ltd., Spiral Binding Company and Spiel Associates for their perspectives on how the on demand market has changed mechanical binding and the ways their companies have reacted to meet the needs of customers and end users.

How has on demand printing changed the market for mechanical binding?

“On demand is basically synonymous with short run,” said Anna Massey, sales and marketing manager for Gateway Bookbinding Systems. “The days of a book run being a half million copies are no more – or most certainly few and far between. To react, mechanical binding needs to be able to handle two books to 200 books quickly, efficiently and cost effectively.”

In an interesting trend that speeds the finishing process by reducing diversification, punch patterns are being standardized and paper houses have started to supply pre-punched paper. “We have seen some standardization for specifications within this level of the market,” explained Massey. However, David Spiel, president of Spiel Associates, noted that buying pre-punched paper can be problematic when covers, tabs or odd-sized sheets need to be intermixed with pre-punched body copy. “Often, punching dies will not match the pitch of the pre-punched paper. Even worse, the paper size of the pre-punched sheets may not match the paper size of sheets that you punch yourself, throwing off the pitch and making coil insertion difficult.”

Matt Roth, vice president at Spiral Binding Company, noted, “As a manufacturer of binding supplies, one of the biggest changes to the marketplace we have seen is that the customer base has shifted from large binderies to smaller print shops.” With customers demanding fast turnarounds and requiring smaller print runs, printers are bringing binding capabilities in-house rather than sending uncomplicated jobs to binding partners. With new digital print shops opening almost daily, Massey also has seen the customer base increase for smaller equipment manufacturers, and the trend shows no sign of stopping.

What changes in either equipment or wire/plastic coil will we see in the future?

“The trend is definitely for equipment to be smaller, easier-to-use, faster and less expensive,” stated Roth. “The most common request we get is for more automation, but binders also want quick set-ups because many of the jobs are short-run.” Spiral Binding Company’s line of James Burn/Lhermite equipment is well-positioned to meet those market needs. Massey concurred with the need for automation, “The on demand printer wants a level of automation that is simplified for ease-of-use to maximize productivity.” Automation also reduces the amount of operator training and intervention that is needed, reducing labor costs.

“The customer is concerned with three things: speed, automation and labor reduction,” said Spiel. “We’ve reacted by introducing machinery designed for speedy, short run mechanical binding, while keeping the need for labor reduction in mind.” Spiel’s Sterling Coilmaster Jr. binds books with either round or oval punch holes automatically, doing the work of six manual binders with operators.

Roth also noted that binderies and printers are looking for a smaller equipment footprint. Massey agreed: “On the equipment side, historically the customer had the choice of either extremely automated high-volume equipment or simple countertop setups. The demand for smaller countertop machines has increased steadily, and in today’s market, the challenge is to build equipment that is fully or semi-automated, but capable of handling the shorter run.” Gateway has built equipment specifically for the digital print market, including the Koilmatic Auto Inserter, a simplified, fully electric version of the company’s more industrial PBS 3000 QS Auto Inserter for trade binderies.

Gateway Bookbinding also is a supplier of plastic coil, and the shift to on-demand book production has signaled a change in the way product is ordered. “The concept of packing coil in 100s is not new, but that option has become important to the on demand customer,” Massey stated. “Minimizing inventory while maximizing availability is the goal.”

Mechanical binding has traditionally been seen as a practical way to bind, rather than an “attractive” option. What can be done to change the perception of spiral coil in terms of design appearance?

“We’d have to disagree with the statement that PLASTIKOIL isn’t an attractive option! With 45 different colors to choose from – along with the option of custom color matching – plastic spiral is a strong, durable binding choice,” said Massey. She continued, “Mechanical binding is selected by the customer for a reason – whether it’s ease of use, durability, application or distribution method – so the customer schoosing mechanical binding view it as their best option and not just as an inexpensive way to bind.”

Roth also defended the appearance and decorative options available with mechanical binding. “It is easier than you think to create custom binding items to make a presentation more attractive. In 2011, Spiral Binding Company purchased a new high-speed pad printer, which allows us to produce more detailed artwork that can be printed right on binding combs and covers.”

Spiel noted that mechanical binding isn’t just plastic coil – double loop wire can enhance end-product appearance as well. “When a plastic coil book is opened, the left page is one half of a pitch lower than the right page,” he explained. “Double loop wire allows the left and right pages to line up, which is especially important when binding books like ledgers or maps. However, plastic coil is much more durable and very kid-friendly, so children’s books that are mechanically bound are most often bound with plastic.”

What is the biggest challenge during production for those using mechanical binding equipment?

“The on demand customer may still view mechanical binding as a tedious task,” explained Massey. “Today’s equipment, however, really does provide very viable solutions. The paper punching process seems to be a stumbling block for many, but there are good, affordable machines on the market that should be considered.” Gateway recommends a .2475″ pitch oval hole pattern as the best choice. According to Massey, the hole spacing fits nicely with the common 8.5″ or 11″ binding edge without the need to pull pins or trim books.

Massey went on to note another stumbling block for operators – ease of use. “The staff of today’s digital print shops often wears many hats – they are customer service reps, purchasing managers, estimators, print production and bindery operators all rolled into one. They don’t operate one machine day in and day out, so today’s equipment has to be user-friendly and easy-to-operate.”

“Like it or not, the market has changed for all binding to demand shorter runs with quick turnaround,” Spiel concluded. Those creating and selling mechanical binding equipment and supplies must react to the shifts in the market by increasing the level of automation available, continuing to champion the pleasing appearance of mechanically-bound products and remaining aware of the trends that will impact both the print customer and end user.

Thank you to Matt Roth, Spiral Binding Company (www.spiralbinding.com); Anna Massey, Gateway Bookbinding Systems (www.plastikoil.com); and David Spiel, Spiel Associates (www.spielassociates.com).

Living in the Mechanical World

August 21, 2007

PostPress

Optimum Bindery was founded in 1990 by Frank C. and Joseph F. Frisoni, Jr. in Nashua, N.H. Frank Frisoni had been a staple in the bindery business since the mid-1960s, first learning to run the machinery and then working his way up in the industry. His forte was in folding and saddlestitching, and he became known as a troubleshooter. Customers would call when they ran into problems and Frisoni would create layouts and set-ups to solve the issue. After years of hearing that he should open his own business, Frisoni founded Optimum Bindery.

The intention was to open a one-stop shop for saddle stitching, perfect binding, and die cutting. After starting out with a small number of basic machines in 3,000 square feet, the company built its way up to having three saddlestitchers, six die cutters, several folding machines, and a Kolbus perfect binder in a facility with more than 21,000 square feet of space. Optimum had a dedicated customer base, drawn by the company’s commitment to meeting turnaround deadlines with high quality work. But something was still missing.

Frisoni had looked into mechanical binding in years past, but hadn’t felt the need to invest in the equipment. As it was, Optimum Bindery was a diversified business already, with enough work to occupy the people and space. But Frisoni saw the economy changing, and decided a change might be looming for his company as well. “Around 2003 the calls for mechanical binding kept growing and growing,” said Frisoni. “It was impossible to ignore. Over half of our customers wanted it done. We refused to do it for a while; then we started researching the equipment. If we already had established customers looking for it, then we knew we were going to have an established base for sales.”

Frisoni had talked to several companies about mechanical binding equipment in the years prior to his decision to add the capability to Optimum Bindery, but ultimately decided on Spiel Associates. “David Spiel was the only one to really respond. He guided me through what I needed to have. The company has case studies and “how to” articles that help you through the early stages of purchasing the right equipment. Plus, its videos demonstrate how each piece of equipment actually works. To make a long story short, David called me a year later to see if I was going to attend the On Demand show in Boston. I told him that I couldn’t make the show, so we struck a deal there and then.”

Spiel was surprised to find that Optimum Bindery had no mechanical binding equipment. “Usually when you visit a bindery there are a few manual coilers around. They didn’t have any so we had to start from scratch. Frank didn’t want to just start with plastic coil, he wanted to bind with double loop wire as well to cover all the bases,” explained Spiel.

Frisoni determined that he wanted to start off with high-speed equipment. “We do 25,000, 50,000, 250,000 runs here. We weren’t going to be able to handle that with manual, tabletop equipment,” he explained. “We started off with Spiel’s new machine, the Sterling Coilmaster Jr.® We really wanted brand new equipment but Spiel had a mint, second-hand Sterling Punchmaster that was reconditioned, and that sounded like a perfect fit. This gave us the additional capital to purchase a brand new Rilecart wire binder with an automatic cover flipper. It eliminates a lot of hand work.” stated Frisoni.

Books being wire bound require the binding element be closed between the last page and the rear cover so that the “seams” don’t show and so that the book opens easily. This requires the operator to flip the cover, closing the book for the end user. The Rilecart TP-480 semi-automatic machine facilitates one operator binding the books and one material handler to box books quickly.

But Frisoni had a problem on his hands – the best kind of problem – too much work! “We decided to get our feet wet with a smaller coil binder and then a tsunami hit us. Our first job was for 30,000 books and we had two more of a similar size on the way.”

The punching was no problem. The Sterling Punchmaster punches over 100,000 sheets an hour, but Optimum couldn’t keep up on the binding. Less than three weeks into the mechanical binding business, Frisoni made the decision to buy a bigger, faster machine. “I decided to jump right in and purchase an in-line plastic coil former and binder, The Sterling Coilmaster III plastic coil binding system. David was kind enough to lend me another Coilmaster Jr. and this let me finish the job I had in-house,” he explained.

The Sterling Coilmaster® was the first automatic inserter and, in-line with the Coilmaker, the first in-line plastic coil former and inserter. It forms the plastic coil as you need it, from spools of filament. “Quite a few of our employees have had experience with various punching and mechanical binding machines, but Spiel’s technician was available to get us set-up and trained on the new equipment. Then the fun began! I really didn’t know anything about purchasing coil or wire, but David did a great job helping me through the first few jobs.” explained Frisoni. “Both Michael (Spiel) and David have spent a good deal of time with me on the phone determining which coil and wire sizes were right for each job. Part of my new learning process included me having to start talking metric. Now we order our coil and wire through Spiel Associates and it generally gets here in a day or two.”

Frisoni is pleased with his company’s introduction to mechanical binding. Jobs are lined up that will keep the shop running twelve hours a day next week. With an automatic punch, a wire binder, an offline and in-line coil binder, Optimum Bindery is well on its way in the mechanical world.

For information on the range of products available from Spiel Associates, call (718) 392-7900.

Plastic Spiral Binding – Problems Solved!

August 21, 2007

by: Anna C. Massey, Gateway Bookbinding Systems Ltd.

Plastic spiral binding is fast becoming the mechanical binding method of choice for many publishers, printers, and binderies. The product’s durability, the vast array of available colors to choose from, and advancements in the automation of the binding process have enabled spiral binding to inch (or coil!) its way onto millions of books each year. Plastic spiral has become a viable mechanical binding alternative to the traditional comb or single and double loop wire types of binding. Knowing what the options are and knowing what the experts recommend can help a company handle any production obstacles encountered when those challenging projects come through the door.

My bindery has tabletop electric punches and coil inserters for plastic spiral binding. The punch has a round hole in a 4:1 pitch. We do okay with books up to about an 18 or 20 mm coil diameter but anything thicker than that slows our output. What can we do to speed things up?

The rule of thumb for plastic spiral is simple. The larger the punch hole and wider the pitch spacing (distance between the holes), the easier the coil insertion process. The 4:1 pitch round hole that is common on most small or mid-range coil punching equipment is great for work that falls between about a 6 and a 16 mm coil diameter. However, if you are doing a lot of work thicker than about 5/8″ you really should consider incorporating a wider 3:1 (3 holes per inch) or 2.5:1 (2.5 holes per inch) pitch punch pattern for those thicker books.

It also is recommended that an oval shaped hole be used (versus a round hole). A hole that measures at least 6.5 x 5.5 mm in size works best. The oval (or “Double-D”) provides more height within the hole for the coil to find its “way down the books” binding edge. And the wider 3:1 or 2.5:1 pitch spacing means fewer holes for the coil to wind through. Oval holes – even in the 4:1 pitch – really speed things up. The larger oval hole, coupled with the wider pitch, will equate to improvements in production of up to 40 percent.

My supplier tells me that 4:1 pitch and 6 mm pitch and .2475″ pitch are all the same stuff, but coil equipment manufacturers tell me their equipment is “pitch specific.” If I punch 4:1 (4 holes per inch), is it important that I use 4:1 coil?

The term “pitch” refers to the distance between the punch holes or the actual loops of coil. For example, a 4:1 pitch means that there are exactly 4 holes within every 1 inch measurement. Should the same pitch of coil that matches the punch pattern be used? Absolutely! The 4:1 pitch is very common. There also are European machines that work with a metric 6 mm pitch. (That means that there are 6 mm from the center of one hole to the center of the next hole). The .2475″ pitch – although very close to the 4:1 / .250″ pitch – centers best on the common 11″ and 8.5″ binding edges without the need to pull any punch pins.

If punching a 4:1 pitch and running a 6 mm pitch coil through those holes, the smaller diameters of coil won’t run as well as they could. Larger diameters of coil are a little more flexible so they are a little more forgiving. There is, however, enough incompatibility between different pitches to affect productivity if the incorrect pitch is used.

When I am quoting a binding job for plastic spiral, I often find that the book production per hour rarely comes in at what I had estimated. Why is there such variation between jobs with the same size of coil?

When estimating a plastic spiral binding job, there are more than just the book’s thickness and binding edge length that need to be considered. The complexity of the book can dramatically affect its run through the bindery. Does the book have tabs? How many? Any inserts or folded pages? Oversized covers? What type of stock?

If a job comes through the door with tabs, the odds are that the tabs (and probably the covers) were punched separately from the body of the book. Unless the utmost care has been taken to ensure precise punch registration, when the components are married together there may be misalignment of the punch holes. Without good, clean punch registration, when the bindery operators go to insert the coil, the coil will get hung up as it tries to find its way through the holes. That slows down production per hour. Make sure the complexities of a project are understood in their entirety before estimating the production output.

There is equipment on the market that would let us manufacture our own coil. When does it make sense to bring this process in-house?

Studies show that when a bindery or in-plant is purchasing approximately $20,000 to $25,000 per year in coil, it is at the point that it makes financial sense to bring the coil manufacturing process in-house. In-house coil manufacturing usually represents a material savings of almost 50 percent. In addition, spools of filament are in stock, allowing the bindery to convert it to the various diameters and lengths required as needed. Inventory floor space is dramatically reduced, transport costs for spools of filament versus countless boxes of pre-formed coil also will be reduced, and the bindery is positioned to respond to its customers’ requirements much faster.

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