Saddlestitching

Saddlestitcher Heads – 7 Deadly Sins to Avoid

June 6, 2024

By Team Technifold USA

As users increase the speed on a saddlestitcher (or any piece of bindery equipment,) they’re likely to see more and more defects as the speed increases. There are many components that make up an automatic inserting, stitching and trimming line, each designed with operating specifications and limits. If any single component is slightly worn or not set correctly, it will prevent the machine from running at its maximum designed speed. Lots of little defects and weaknesses can add up to big losses in productivity.

The stitching head is one especially critical area for proper operation of a saddlestitcher at any speed. Even the simplest of newer stitching heads is a complex piece of equipment which, if not properly handled, will cause slowdowns, poor-quality stitched books and machine downtime.

In a conversation with Dave Double of Double Equipment, which specializes in bindery equipment repairs, including servicing of stitcher heads, it was brought to light the seven common but costly mistakes that stitcher operators and bindery managers make with their stitcher heads.

1) Using the wrong lubricant. Several common heads use a one-way bearing in their wire-advance system. Operators often use the wrong grease which, at higher speeds, results in varying leg lengths in the stitch. This leads to a frustrating troubleshooting expedition where the operator is trying to ‘fix’ a head that simply requires the correct grease.

Also, stitcher manufacturers usually recommend light machine oil and not the automotive oil which often is used. Be sure to use precisely what is recommended.

2) Using the wrong amount of lubricant. Any stitcher operator who’s been around a while has made this mistake – put too much oil somewhere on the stitcher head and the next few thousand books are a nightmare! Excess oil makes its way through the head and through the rest of the machine. In extreme cases the only solution is to remove the head for disassembly, cleaning and proper oiling.

All that typically is required is ONE drop at the proper location and at the proper interval. If the recommendations say one drop per eight hours of running, make sure that it’s not two.

3) Using the wrong wire gauge for the job at hand. Two of the most commonly used wires are 24 and 25 gauge round stitching wire. They are good all-around wires for most commercial bookbinding and print finishing applications. But if the operator stitching a 3/16″-thick book, or slightly heavier, the 25 gauge is approaching its limit. Problems can arise when near the limit and running at high speed. If the operator goes beyond the thickness limit, he or she is almost certain to encounter new problems.

When stitching an extra-heavy or extra-thin job, be sure to use the best size of wire for the job at hand. It is not common to saddlestitch books beyond 1/4″ thick, but if an operator does and runs into problems, don’t forget to check wire gauge.

4) Using the wrong wire gauge for the stitcher head. Each stitcher head has its own suggested limits on wire gauge. Be sure to check the limitations of the wire gauge for each particular saddlestitcher.

5) Using inferior wire. Wire quality varies considerably among manufacturers. Some factors that affect stitching wire performance are tensile strength, consistency of wire size, cleanliness, resistance to flaking, type of coating and type of alloy.

For instance, an inexpensive galvanized wire may start to flake and/or leave excess wire shavings when cut inside the stitcher head. This, in turn, will clog the head and cause premature wear on numerous internal parts. It also can make it difficult to get a properly formed stitch at higher speeds. Generally speaking, a tinned wire or a premium galvanized wire will run better, with less flaking and a more consistent coating, cleanliness and strength. If a facility does enough stitching, consider the larger 70# spools equipped with a de-reeler. These are not wound as tight as the smaller spools, so there is less variation due to changes in the wire curl.

6) Lack of regular servicing. Stitcher heads need regular maintenance, lubrication and service. If a finisher or binder doesn’t have someone on staff who is qualified to rebuild and repair stitcher heads, send them out regularly to someone who can. It is money well spent that will keep the stitcher running smoothly.

7) Instruction manuals that never get opened. Each model has its own special requirements and peculiarities. It’s been said a person can learn either through wisdom or suffering. There is wisdom gleaned from reading the manual.

There have been instances when operators have transitioned to a different saddlestitcher, needed to install a new stitcher head and simply didn’t consider the differences in the saddlestitcher. This can cause enormous damage to the machine and head. Installing the wrong head can turn into hundreds or thousands of dollars in repairs.

No matter which stitcher head is being used, be sure it’s set correctly to give a good cut, consistent wire draw, equal leg lengths, proper clincher and clincher alignment, and correct compression.

Most bindery equipment operators like to have a performance edge available to them when they need it, especially if they want to go home early! Although running at maximum speed is not always the best way to get maximum yield, it sometimes is both possible and necessary. On those occasions when a bindery must run at maximum speed, it’s nice to be able to do it without gremlins like those mentioned above slowing operations down. The good news is that these stitcher head tips are simple to follow.

Thank you to Technifold USA for its assistance with this article. For more information, visit www.technifoldusa.com.

Tech Watch: Horizon iCE StitchLiner Mark IV Saddlestitcher

November 27, 2023

Edited by Erin La Row, editor, PostPress

Standard Finishing Systems, located in Andover, Massachusetts, combines scoring, folding, saddlestitching and trimming into one system with its third-generation Horizon iCE StitchLiner Mark IV Saddlestitcher. Compared to previous generations of StitchLiners, the Mark IV features more automation; customizable machine status indicator lights; easier system access points for operators and technicians; more flexible configuration options
for both offset and digital output; improvements to key areas like feeding, scoring and jogging; and built-in connectivity for Horizon’s iCE LiNK.

“The Mark IV StitchLiner was designed with variable thickness booklet production in mind,”
said Don Dubuque, director of marketing for Standard Finishing. Stitch length, balance adjustment, registration guides, trim size and more all can be changed automatically during production, giving print providers the ability to run a wide range of booklet applications on the Mark IV without being slowed down by manual changeovers.

“Achieving true variable production has been a challenge for print providers running booklet applications. Downtime during changeovers is costly, and manual changeovers require skilled labor that is hard to find in this market,” Dubuque said. “By automating this process and optimizing the machine to produce high-quality booklets across thicknesses and substrates, the Mark IV reduces those costly changeovers and lets operators work more efficiently without requiring advanced skill sets.”

The Mark IV can run at speeds of up to 6,000 booklets per hour for A4 portrait applications and up to 5,300 books per hour for A4 landscape applications. It can maintain these production speeds while in variable thickness mode or even when cover sheets are being inserted.

The system’s scoring function reduces cracking on the spine and allows for a tighter fold across all booklet sizes. Depending on the substrate, the gap and scoring pressure can be adjusted for consistent scoring quality. The sheet-alignment section of the Mark IV features 4-directional jogging for a tighter jog and more accurate alignment across stocks. Improvements to Mark IV’s transport system also allow for stable sheet transport across substrates, even for coated sheets. Additionally, the feeding end can be configured for offset or digital print output and can be integrated with Horizon VAC series collators and
the HOF-400 high-speed sheet-feeder.

The Mark IV also is iCE LiNK ready. iCE LiNK is Horizon’s cloud-based information and diagnostics tool that allows for production management across multiple finishing devices to provide a higher level of operational efficiency by offering items like KPI capture to verify productivity, preventative maintenance alerts, job scheduling and seamless workflow
for job changeover.

Dubuque said customer response to the Mark IV during product demonstrations at Standard Finishing’s National Demonstration Center in Andover, Massachusetts, has been positive, and several customers already have placed orders.

“Horizon’s StitchLiner Mark III was one of our most popular solutions, and customers are excited to see the changes Horizon made for the Mark IV,” Dubuque said. “It’s a machine
built for today’s print environment.”

Preparing for Today’s Bookbinding Applications

September 16, 2022

By Dianna Brodine, managing editor, PostPress

At the height of the pandemic, a significant increase in durable goods orders kept manufacturers producing at near record levels. Consumers who found themselves at home hit “add to cart” as they made purchase decisions on items to make their living spaces and daily lives more comfortable, including furniture, home appliances and entertainment options. One surprise winner in this shopping spree? Books. Even more surprising, the
spree continues.

According to a report from market research company NPD Bookscan, unit sales of print books increased 8.2% from 2019 to 2020, with 693.7 million print units sold. In 2021, 825.7 million units were sold – an increase of 8.9% in 2021 over 2020. Some of the early sales numbers were driven by panicked parents looking for resources that would replace educational opportunities lost when schools closed. However, with school back in session, young adult fiction books were the biggest driver of the 2021 increase, with unit sales jumping 30.7% according to NPD. Adult fiction sales rose 25.5%.1

Photobooks are another print industry staple that benefitted from consumers with time on their hands. Many took advantage of the opportunity to scan family photos or finally do something with the images on their cell phone cameras. Digital photobook production sites such as Shutterfly and Snapfish added new book sizes, paper stocks and design options to keep up with demand.

Two industry experts – Rick Salinas, president of Duplo USA, and Al Scolari, president and CEO of APS Imaging Solutions, Inc. – spoke about the trends in bookbinding during Amplify Print in Minneapolis, Minnesota, a first-time event aimed at those involved in print embellishments. During a panel discussion, Salinas and Scolari answered questions about binding processes on the rise, tactile effects, paper challenges and more.

Layflat and perfect binding take off during the pandemic

APS Imaging Solutions is a leading provider of digital lay flat photo book manufacturing systems and accessories to professional photo labs, photographers and studios worldwide. Over the last few years, Scolari has witnessed a surge of interest in lay flat binding, driven by an automated process that makes photo book production more accessible. “We specialize in the panoramic, full-image spread,” he explained. “That type of image is ideal for lay flat binding, and the professional photography market has taken notice. Over this two-year time period when everybody was at home, we’ve seen more photo books being generated – and that came along with a 30% increase in photo books done with perfect binding.”

Duplo USA Corporation also witnessed the growth of perfect binding. The company is the leading provider of print finishing solutions for the graphic arts industry, with highly efficient, modular products that streamline postpress production for digital color and offset applications. “Over the two years of COVID-19, perfect binding was absolutely explosive,” Salinas said. “People were trapped at home and bored, so they started ordering printed books again on sites like Amazon. That created a challenge because these days, when you order a book from a retailer’s website, that book doesn’t exist on a shelf.”

On-demand printing and inexpensive file storage changed the traditional book production and warehousing process. Now, when an order is placed, a file is downloaded and sent to the print facility closest to the consumer’s location. The interior pages are printed, a cover is manufactured and, within a couple of days, the book is on its way for delivery.

“Automation has taken book production to the next level,” Salinas said. “Paperback books are manufactured with this easy, on-demand perfect binding process, and now online booksellers are applying the same automated process to hardcover and lay-flat books to reduce storage costs and avoid low margins when stored books are sold to wholesalers.”

The visual and tactile effects of books

“Embellishments create intrinsic value out of nothing,” said Salinas. “Studies have shown that the more a product can touch the senses – see, touch, smell – the more it entices buyers. So, we see book covers that are foil stamped, embossed, debossed or finished with a soft-touch coating.”

Those print embellishments add visual and tactile elements to the cover of a book, drawing attention on a retail shelf and then enticing the consumer to pick a book up and hold it. This “haptic marketing” focuses on the tactile sensations that create a pleasing experience.

“Through studies, we know that if we can get a consumer to hold onto something, the brain begins to create ownership,” Salinas said. “So, the longer retailers can get purchasers to hold a book in their hands, the more chance there is that consumers will get hooked and take the book home. And, the more unique, the better! People don’t want a traditional book size anymore, so letter landscape formatting has become very popular. Duplo has just released our I Saddle 5.0, and every page in the book be a different size. Those unusual features increase the likelihood of purchase.”

Binding techniques play a critical part in that visual and tactile appeal. Lay flat binding appeals to the high-end coffee table book market. Saddlestitching can be done with an exposed, colored thread that adds a visual ‘pop.’ And raw edge paper adds another point of interest.

Scolari added, “It is all about creating something different. In some of our lay flat binding projects, whether children’s books or other types of printed books, we’ve added multiple inserts to build a thicker page that is extremely stiff. We’ve also had requests for the ability to use different types of substrates in one book, so one page will have a matte finish, but when the page is turned, the next image has a luster or metallic look.”

“Smell is probably the one sense that hasn’t been attacked yet in the printing industry, but I think we are going to start seeing it,” Salinas predicted. “Raised spot UV is something we’ve been doing for a number of years, and I think we’ll eventually see scented polymers come out as another way to attract buyers.”

Paper challenges in book production

Recycled paper stocks are another trend embraced by consumers. But, those stocks can cause problems with equipment throughput or adhesive bonding.

“The problem with recycled paper is that it’s recycled,” Salinas laughed. “To create a good-looking sheet, pulp and clay have to be added. It’s also a cost-cutting measure for paper manufacturers because the actual paper content in paper has gone down significantly. Clay is an inexpensive way to build up a piece of paper, but it can flake off during binding. Then the equipment or adhesive are blamed for failures, but oftentimes the substrate is the issue.”

Synthetic paper, often manufactured from plastic films, has gained in popularity due to its durability. “Synthetic paper looks beautiful when laid perfectly flat, but it doesn’t like to fold,” Salinas explained. “It’s hard to cut, and it’s very hard on the blades. We tell people that Duplo equipment can cut two million books on a single blade, but synthetics often reduce that significantly.”

Scolari said thicker, less flexible substrates also have an impact in the photobook production process. “We score everything with lay flat binding. So yes, we can use many different substrates and prints, but it’s very, very challenging to score a substrate that is stiff. The synthetic papers – and even some of the recycled substrates – can show discoloration after scoring. Sometimes, it’s better to look at a coil binding or perfect binding process.”

Focusing on the elimination of waste

A key component of today’s sustainability conversation is the reduction of waste. Automation is critical in the on-demand world of book production, where a print run may consist of just one book.

“The word ‘makeready’ is a thing of the past,” said Salinas. “When a run length is 13 sheets, you can’t have a 3% or 5% makeready margin. Automation is the only way to achieve zero makeready, and that has to be the ultimate goal for an operation that claims sustainability because every sheet that goes into the trashcan – that isn’t sellable – is created waste. Job flow software that ‘talks’ to the book production equipment as a print job moves through the system facilitates the elimination of waste.”

Scolari knows all about book-of-one production, since most photobooks are one-off orders. “It’s really about automation in regard to the layout, the tiling of the pages. It’s utilizing the material, especially when we’re using leather or other high-end materials. We use an overhead system that projects a tiling layout to eliminate waste and use each material in the most efficient way.”

There’s another often-overlooked source of waste in book production. “In the vast majority of printers in the US, the production staff has no idea of how much time they are wasting between steps,” Salinas explained. “If it takes 20 minutes to print, 20 minutes to bind and 20 minutes to ship, how much time is wasted in between those steps while walking the book block from the printer to the finishing device and then over to the packaging and mailing department?”

Understanding workflow is the first step in eliminating unnecessary steps during the production process. “Before print shops go out and buy a piece of equipment to improve their throughput and speed up production, they have to understand where they are wasting time,” Salinas said. “Then they will understand how to automate their processes to drive out the touch points, increase profits and reduce the chances for error.”

In a world where the printed book has made a comeback, but without the volumes of yesterday, automation is worth the investment.

References
“Print Books Had a Huge Sales Year in 2021,” Jim Milliot, Publisher’s Weekly, Jan 06, 2022, https://www.publishersweekly.com/pw/by-topic/industry-news/financial-reporting/article/88225-print-book-sales-rose-8-9-in-2021.html

Quality Stitching Wire Matters

March 10, 2017

by Kristopher Shaw, sales manager, WCJ Pilgrim Wire

Stitching wire is one of the last items a printer or binder thinks about; however, there have been some interesting changes with stitching wire in the last few years, including the increase in the use of colored stitching wires (PET coated and alloys) and the use of stainless steel wires used in specialty production runs. The wires used in binding or finishing departments are in the form of saddlestitching, loop stitching, bookletmaking, side stitching, inline press stitching and corner stitching.

As the industry has evolved, so has stitching wire. Quality of wire, path of wire, wire delivery, spool sizes and de-spooling equipment are all major factors in how stitching wire is going to perform in the field. With the continued demand for increased run speeds and overall profit, high-quality stitching wire and proper machine set-up are a must for today’s binding/finishing departments.

Quality of wire

An ideal wire is chrome-like in appearance with special friction-reducing additives to resist peeling and flaking. It provides a superior workability while forming into a staple.

Stitching wire is not straight. Each wire package has a desired curvature of the wire. The radial or circular curvature is known as “cast.” Cast is measured as the diameter of a free turn of wire. The axial component is referred to as “camber.” Camber is measured at the offset in the ends of one turn of freely hanging wire. Larger cast and smaller camber are characteristics of a high-quality wire. This allows the wire to go into the stitching head more smoothly, producing less drag, and will provide fewer dropped stitches. In turn, the stitching head will work more efficiently with less energy and with less maintenance. So, checking on the straightness of the wire can be very important.

Path of wire

A clean path for the stitching wire from the spool to the stitching head is critical in getting a positive stitching outcome. The coating can be easily chipped, scraped or damaged by running the wire past an unprotected steel bracket, worn wire guides, spring tubes or dirty felt pads. The felt pads must be checked frequently, oiled and rotated, or replaced, on a regular schedule. Wire guide springs and felt pads are a normal wear part on any stitching head. Flat spots on guides and springs, along with a dirty felt pad wiping system, can cause flaking issues that will jam the stitching head, stop production and cause additional maintenance and repair costs.

The right size wire for the job

The majority of stitching wires used in today’s binderies and inline stitching operations are 24 and 25 gauge. These two gauge sizes amount to a 21.3 percent difference in product yield, which translates into 21.3 percent more staples when using a 25 gauge over 24 gauge. In simpler terms, imagine if a staple or stitch is one inch: that would allow for 2,304 more staples by using the 25 gauge wire over 24 gauge.

Recommended stitching wire gauge

25 gauge stitching wire is the recommended thickness for work that is 1/16 to 7/32 of an inch.
24 gauge stitching wire is the recommended thickness for work that is 1/16 to ¼ of an inch.

These are only suggestions as paper type, density, coatings and stitcher set-up can change the stitching wire size required. Larger diameter wire substantially affects the yield of the wire, along with the increase in the amount that will be paid in postage.

Spool sizes, de-spooling equipment and winding

Stitching wire comes in many different packages and generally ranges from 5lbs to 1,000lbs in size. Primary usage and machine type determines the size of spool required, but running speeds and space availability also play a crucial role.

Standalone stitchers that are hand fed usually use five or 10lb spools. Collators with stitchers used for short-runs of five to 10,000 books also can use this type of spool. Saddlestitchers for longer, mid-range runs will use 35, 40 and 70lb spools. High-speed collator/stitchers and web operations using inline stitchers will use 200lb, 650lb smart-drum and even larger 1,000lb smart-pull wire systems.

A larger spool or drum has economical and production advantages. Larger packages cost less per pound of stitching wire to manufacture, and larger packages require fewer spool changes during the manufacturing process.

Utilizing larger wire packages will reduce spool changes, thus increasing the output of books per hour. A normal spool change averages two minutes per spool changed, and generally a saddlestitcher runs anywhere from two to four stitcher heads at a time. With four stitcher heads running a job of over 100,000 pieces with 5lb spools, a saddlestitcher would be stopped for spool changes a minimum of 16 minutes alone. Changing to a 35lb or 40lb spool would wipe this changeover time to zero.

Different size packages have different characteristics that can give the end user advantages. For instance, as stated earlier, a larger circle diameter improves the performance of stitching heads with less friction due to less straightening required and fewer dropped stitches. The larger diameter packages, such as the 650lb smart-drum and 1,000lb smart-pull spools, have larger circle diameters to improve stitcher head performance since less straightening is required.

Proper de-spooling equipment is essential to complement the high-quality wire being used. Matching the correct de-spooler with the spool is essential to problem-free production.

Kristopher Shaw is the sales manager for WCJ Pilgrim Wire. To learn more on WCJ Pilgrim’s full line of stitching wire and related products, visit www.wcjwire.com.

Saddlestitching Industry Evolves as Some Printers Move Function In-House

August 21, 2013

by Jen Clark, The Binding Edge

As equipment manufacturers develop machinery that can handle both digital publishing and finishing capabilities easily and efficiently, some trade binderies have seen a drop in work orders for saddlestitched products, which traditionally had been a large segment of their business. For others, as the work remains steady, new developments in saddlestitching equipment and supplies offer a crucial competitive advantage.

Sonja Nagy, chief operating officer of Texas Bindery, Cedar Creek, TX, said the family-owned trade bindery has seen a substantial drop in saddlestitching work as technology advances and printers choose to keep that kind of work in-house. “Most of the newer digital equipment have inline saddlestitching features,” she said. “Before the advent of digital equipment, customers would send out the work and not be concerned with keeping all the functions of production within their own facilities.” Now, Nagy explained, printers are saving time and money by keeping saddlestitching in-house and inline. “For printers, theres a cost savings when a book comes off of a digital production line, even if it is produced at a slower speed, because it still is being done inline.”

Conversely, Dan Griffin, president and founder of Binderyonics in Elk Grove Village, IL, explained that the type of customers courted by his business means that digital technology hasnt affected his saddlestitching volume that much. “We are a large-volume trade bindery, producing items like catalogs,” he said. “Our customers are all large web printers, and they still are sending out work. For the sheet-fed binderies, though, I think (coping with digital) has been a real struggle.”

Texas Bindery has three high-speed saddlestitching machines on its production floor, but they are rarely used, Nagy said. “Last year, they were some of our busiest machines, but now most of the material is being produced in another country or the print publication has converted to a digital-only option,” she said. “We used to do a lot of computer manuals and larger client orders producing millions of books a year from sheet-fed and web printers. This year we will produce one-fifth of what we have in the past. The majority of the web presses in our area have closed their doors. Sheet-fed printers have in-house saddlestitching capabilities; and with the tightening of the market, they will rearrange their schedules to keep production in-house if possible. Every year is a new adventure with all the changes that continue to occur in this industry.”

There are times when saddlestitched items can’t be produced in-house, though. “What we do see is more specialty work – large-format, loop stitching, two-up production runs, pocket folder covers, laminated covers or oblong books that don’t fit in-house production parameters,” Nagy said.

Binderyonics sets itself apart from the traditional trade binderies by getting into the mailing and fulfillment business, allowing it to offer binding and mailing under one roof. The items produced at Binderyonics, Griffin said, need to be folded, stitched, cut and mailed. Saddlestitching “is a very cost-effective,” he said. “For clients, it remains an inexpensive process to make the finished book.”

Some of the industry’s latest developments include saddlestitching machines that are highly automated, operator-friendly units that produce books quickly and efficiently. For large jobs, the Osako Micro saddlestitcher from Best Graphics, Menomonee Falls, WI, boasts high levels of automation, fast speeds and the ability to produce thick books. Other features include speeds up to 9,500 bph; 15-second stitch head, clincher and chain positioning; tilt-back, tool-free signature feeder set-up; pull guide fold system cover feeder design; and continuous oil bath circulation in the stitcher and trimmer. Options on the unit include syncro start and stop, downstream inhibit and 4th- and 5th- knife capability.

The DBMi Saddle System from Duplo USA, Santa Ana, CA, is a heavy-duty, high-volume collating and saddlestitching system that is the first in its class to deliver the increasingly popular letter landscape booklet. Designed to handle both offset work and short-run digital jobs with equal ease, the fully automated DBMi combines PC-based programming and intelligent feeding with superior scoring and folding to produce up to 4,500 booklets per hour. In addition, its modular design enables users to add three-knife trimming capabilities with the optional DKT-200 two-knife trimmer and gutter cutter, which also can process 2-up applications, boosting its production up to 9,000 booklets per hour.

The Stitchmaster ST 500 from German manufacturer Heidelberg, with US headquarters in Kennesaw, GA.

German manufacturer Heidelberg, with US headquarters in Kennesaw, GA, developed the Stitchmaster ST 500 with individual drive technology, a centralized control system, wide range of feeder models and high automation level. The all-purpose machine, ideal for industrial saddlestitching, can be put to use for a wide range of tasks in next to no time. It can be fitted with vertical, horizontal and cover folder feeders for maximum production flexibility. Automation options for the feeder, trimmer and stitcher – including a quick-change rig for stitching heads and compensating stacker – cut makeready times and enable efficient, high-output production.

The DeLuxe M19-AST Stitcher from Spiral James Burn, Totowa, NJ, is a single-head machine designed to accommodate both light- and heavy-duty work and can stitch in both flat and saddle formats. It is ideal for smaller binderies because it has a 3/4″ capacity and a range of crown sizes. The stitcher can accommodate eight different wire sizes without changing parts. It also accommodates both the traditional style 18D stitcher head and the side-feed style G20 head. The M19 is foot-switch operated and belt driven by a 1/2 HP motor, for cycle speeds of up to 200 stitches per minute.

The Standard Horizon StitchLiner 6000 from Standard Finishing Systems, Andover, MA.

As the demand for smaller, high-quality books has increased, so have the saddlestitching solutions for producing these booklets. The Standard Horizon StitchLiner 6000 digital saddlestitcher from Standard Finishing Systems, Andover, MA, is fronted by Standard Hunkeler unwinding and rotary cutting technology and allows customers to process from roll to full-color, finished booklets in one continuous process with no intervention or manual touch points. This solution offers inline cover feeding and non-stop booklet production on a wide range of paper stocks at up to 600 per minute, on pace with the speed of industry-leading continuous-feed printers. Variable sheet-count booklets can be produced using barcode scanning or mark reading. An optional high-speed sheet feeder can be added to run from a roll or cut sheets.

The Stitch-Fold from MBM Corporation, Charleston, SC.

Wire-fed technology from MBM Corporation, Charleston, SC, saves customers time and money. The StitchFold is capable of producing high-quality booklets quickly and efficiently and offers features found in larger, more complicated machines. StitchFold replaces staple sticks with spools of wire, saving money while eliminating the need to stop mid-run to replace staple cartridges. It can produce 2,300 booklets per hour – up to 65,000 without having to replace wire spools – and runs inline with a variety of collators. The optional trimmer completes the finishing system.

The FB500 stitching wire spool from WCJ Pilgrim Wire, Glendale, WI.

Using premium wire with a stitching system also can dramatically increase line productivity and eliminate the waste caused by throwing away half-empty spools of wire. The high-capacity FB500 stitching wire spool from WCJ Pilgrim Wire, Glendale, WI, offers to increase production, bring additional cost savings and add safety to the bindery. The 1,000lb spool increases efficiency with fewer stoppages. Its straight winding technique produces straighter wire that is easier on stitching head parts. The system requires no costly de-spoolers, dollies or lifting devices. It also requires no heavy lifting. The wire stays put while an operator positions the stand and trouble-free pulley system. The stand and spool have a footprint of 24×39″ and measure 72″ tall.

A Closer Look at Stitching Wire

August 21, 2012

by: Kris Shaw, WCJ Pilgrim Wire

In today’s commercial printing industry, stitching wire is used in two areas – the bindery and pressroom. Stitching wire is a low-carbon steel with a galvanized or tin coating. Stitching wire is used in the bindery or finishing departments in the form of saddlestitching, bookletmaking, side stitching and corner stitching. A more recent trend WCJ Pilgrim Wire has seen is growth in the use of stitching wire for the pressroom in high-speed web operations in the form of inline stitching.

Stitching wire has evolved as the industry has changed and now is a highly tuned part of the printing world. Quality of finish, size, cast, camber, tensile, path of wire, wire delivery, spool size, and despooling equipment all are major factors in how stitching wire is going to perform in the field. With the continued demand for increased run speeds and overall profit, high-quality stitching wire and proper machine set-up are a must.

Stitching Wire Attributes

Quality of Finish. An ideal wire is chrome-like in appearance with special friction-reducing additives to resist peeling and flaking while providing a superior workability in all bending and forming applications.

Cast and Camber (Helix). Commercially produced, stitching wire is not straight. Each spool size has a desired curvature of the wire. The radial or circular curvature is known as “cast,” which is measured as the diameter of a free turn of wire. The axial component is referred to as “camber,” which is measured at the offset in the ends of one turn of freely hanging wire. A large cast and small camber are characteristics of a high-quality wire. This allows the wire to go into the stitching head smoother, producing less drag and providing fewer dropped stitches. The stitching head will work more efficiently with less energy and maintenance.

Tensile. Tensile is the pull required to break the stitching wire and is measured in pounds per square inch (PSI). The higher the breaking point the stiffer the wire. High-quality stitching wire has a tensile range of 135,000 to 165,000 PSI. A tensile above 165,000 PSI will wear out parts in your stitching head prematurely, causing maintenance costs and downtime. High-tensile wire also can wear out the knives in a trimmer section prematurely. The increased hardness of the stitching wire will nick a trimmer sections knives more severely when struck during saddlestitcher jams. A tensile below 135,000 PSI will cause the stitching wire to be soft and will not properly form a stitch.

High-tensile stitching wires are available, but the cost benefits of using a high tensile wire with a thinner diameter on thicker applications is outweighed by the cost of premature wear on stitching heads and trimmer section knives.

Path of Wire. A clean path for the stitching wire from the spool to the stitching head is critical in getting a positive stitching outcome. The coating easily can be chipped, scraped and damaged by running the wire past an unprotected steel bracket, worn wire guides, spring tubes and dirty felt pads. These areas must be checked frequently and rotated or replaced on a regular schedule. Wire guide springs and felt pads are a normal wear part on any stitching head. Flat spots on guides and springs, along with a dirty felt pad wiping system, can cause flaking issues that will jam your stitching head, stop production and cause additional maintenance and repair costs.

Types of Wire. Electro-galvanized stitching wire is the most widely used type of wire in the printing industry. Today’s friction- reducing electro-galvanizing process provides a smooth burr-free finish that works well with small-, medium- and large-size binderies and inline web stitching applications.

Tin-coated stitching wire still is used in a small number of binderies and finishing departments. Because of the small number of tin wire users, the cost is higher than electro-galvanized stitching wire. Tin wire adds little or no added value to the stitching process or the stitching head.

The Right Size Stitching Wire for the Job

The majority of the stitching wire used in today’s binderies and inline stitching operations is 24- and 25-gauge. The difference in size from 24-gauge (0.023-in.) to 25-gauge (0.0204-in.) is 0.0026-in. This small amount may seem insignificant, but it means a lot in terms of yield.

A 24-gauge wire has 8,496 inches per pound of wire, and 25-gauge has 10,800 inches per pound. This amounts to a 21.3 percent difference in product yield, which translates into 21.3 percent more staples if you use 25-gauge over 24-gauge. In simpler terms, if you imagine a staple or stitch being one inch, you would have 2,304 more staples by using the 25-gauge wire over the 24-gauge.

Choose the right wire for the job:

25-gauge stitching wire’s recommended thickness of work is 1/16 to 7/32 of an inch.
24-gauge stitching wire’s recommended thickness of work is 1/16 to 1/4 of an inch.

These are only suggestions, as paper type, density, coatings and stitcher set-up can change the stitching wire size required. Physically check the size of your stitching wire and don’t believe what is on the label until you are sure. An oversized wire that is labeled 25 gauge but actually is larger in size means you are not getting what you are paying for. Oversized wire substantially affects the yield of your wire along with increasing the amount you end up paying at the post office.

Location and Inventory of Your Source

Does your wire provider have a facility or warehouse in the proximity of your location? As an extremely heavy commodity, shipping costs are some of the primary contributors to the end price of your stitching wire products.

Weigh out the cost savings of having a localized source and your freight expenditure. Will taking more stitching wire create a bigger savings for you?

Spool Sizes, De-Spooling Equipment and Winding

Stitching wire comes on many different spools and generally ranges from 5 lbs. to 1,600 lbs. Primary usage and machine type determines the size spool you require, but running speeds and space availability also play a role. Standalone stitchers that are hand fed usually use 5- or 10-lb. spools. Collators with stitchers used for short runs of 5 or up to 10,000 books can also use this type of spool. Saddlestitchers for longer, mid-range runs will use 35-, 40-, 70-, or 100-lb. spools. High speed collator/stitchers and web operations using inline stitchers will use 200-, 250-, 1,000- and 1,600-lb. spools. A larger spool of wire has both economical and production advantages. Larger spools cost less per pound of stitching wire to manufacture. Larger spools require fewer spool changes during the manufacturing process.

During the binding process, larger spools prevent stoppages of the line for spool changes, thus increasing your books-per-hour output. A normal spool change averages two minutes per spool changed, and generally a saddlestitcher runs anywhere from two to four stitcher heads at a time. With four stitcher heads running a job of more than 100,000 pieces with 5-lb. spools, you would be stopped for spool changes a minimum of sixteen minutes alone. Changing to a 35-lb. or 40-lb. spool would wipe this changeover time to zero.

Different sizes of spools have different characteristics that can give the end user advantages. For instance, as stated earlier, a larger circle diameter improves the performance of stitching heads with less friction due to less straightening required and fewer dropped stitches. A 35-lb. spool, which is flatter and has a wider diameter, has a larger circle diameter than a 40-lb. spool, which is taller and has a narrower diameter. The larger diameter spools, such as the 200-, 250-, 1,000- and 1,600-lb. spools, have larger circle diameters, improving stitcher head performance since less straightening is required.

Proper de-spooling equipment is essential to complement the high-quality wire used. Matching the correct de-spooler with the spool is essential for problem-free production.

How a spool is wound is important especially when the larger spools (200-, 250-, 1,000- and 1,600-lb. spools) are statically (the spool does not move) de-spooled. When a spool is standing on its end, conical winding (winding that is wider at the bottom than at the top) prevents the wire from “falling” as it de-spools. This can prevent wire tangles and jamming. Conical winding needs to be done very precisely during manufacturing to prevent problems. Smaller spools (100 lbs. and less) do not have to be conically wound in order to de- spool properly.

Straight winding is fine for smaller spools that are dynamically paid off (the spool moves on a spindle) and needs to be done correctly by evenly winding the wire across the spool. The stitching wire cant build up in an area, as this could cause tangles. Straight winding on statically de-spooled larger spools is helped by the use of a proper de-spooler.

Green Initiatives: User and Producer of Print

User. Unstitched flyers, advertisements and newspapers produce more litter. Stitched pieces require only one item to pick up and recycle. Steel staples in recycled paper easily are accommodated by typical recycling facilities worldwide.
Producer. Does your stitching wire supplier provide a spool and skid return program? Reusable spools and recyclable products are the way of the future. Throwing away spools amounts to throwing away money in landfill costs.
CPSIA. The Consumer Product Safety Improvement Act requires all stitching wire to have less then 100 parts per million of lead content. Make sure you are using a certified stitching wire product. A product recall could be very costly.

Using stitching wire is a profitable binding solution; it has a low cost and gives a high value.

Kris Shaw is sales manager for WCJ Pilgrim Wire. WCJ Pilgrim Wire maintains high standards for the manufacturing of wire through a series of checks and balances, assuring the final product meets and exceeds customer expectations. The company prides itself on the years of experience its employees have in providing knowledgeable advice and recommendations to its customers. For more information, call 414.291.9566 or visit www.wcjwire.com.

The Importance of Stitching Wire

February 1, 2012

by: Harry Lewis, Dorstener Wire Tech

Saddlestitching has been successfully used as a binding process in print media for many years. The simple, low cost process is ideal for catalogs, brochures, calendars, annual reports and many more binding needs.

It’s important to the industry because saddlestitching offers a choice in the binding process, with benefits and characteristics that outperform other methods. Stitching is simple to lay out, fast to process and, with the third stitch application, offers long life expectancy that outlasts that of a product produced using perfect binding technology. Saddlestitching has better cross-over properties, enhances the center spread ad space and allows for a smaller chance of product failure due to its simple design.

The benefits to companies using stitching over perfect bound technology include low investment costs, low maintenance and lower capital equipment cost. In addition to cost factors, stitching provides a safe, predictable profit margin. Unlike perfect bound technology, stitching is safe for both equipment operators and the environment. Stitching is the answer for a low-cost, flexible solution for binding needs.

How Does Stitching Impact the Bottom Line?

With proper set up, a company is ensured profitability with stitching. This simple, straight forward application makes it easy to estimate jobs, unlike more complicated forms of binding. A company’s profitability is dependent upon reduced down time and maximum operating speeds. Operator experience, excessive downtime and low-quality wire all are factors which contribute to frustrations in the stitching department.

In order to achieve success and increase profitability, a company must recognize that trained and knowledgeable operators are essential to a companys output. The choice of high-quality wire and the proper set-up of the stitching line all contribute to a companys profits. Poor performance of stitching wire is one of the most costly issues in the bindery today. A wide range of issues can arise when running low quality wire, including operator frustration, unexpected down time, excessive head repair and slower production speeds just to name a few. Low quality wire can cost a company thousands of dollars per year. When a stitching line is down for just 10-15 minutes in an eight-hour shift, the cost can be more than $50 for one 15-minute stoppage. If a company has a three-shift operation running five days a week, the cost would add up to greater than $40,000 per year for just one line, all due to a 15 minute stoppage due to a lack of quality in a basic supply item. If a bindery has a low performing stitching line, upgrading to a premium wire could be the answer. The solution to many of the common saddle stitching issues can be overcome by utilizing a high quality wire. A high quality wire will not flake, is pre-lubricated and is spooled properly on a strong, reliable spool.

High quality wire is a definite factor in the performance of the stitching process. Dorstener Wire Tech has implemented a system incorporating high-quality wire with newly designed de-spooling equipment, transport carts and the proper spool size to compliment the high-speed stitching lines. A company should consider each phase of the stitching process, but most importantly, the choice of wire.

What Factors Should be Considered When Purchasing Wire?

Wire is often thought of as a simple product that is just another commodity, when in fact it means the difference between making or losing money on many jobs. Is a high quality wire being used in the binding process? Does the vendor know where the wire is made? Does the vendor have control over the quality of the wire? Does the wire comply with consumer product safety concerns (for example, what is the lead content)?

There are three major factors to consider in the quality of wire:

Surface condition and tensile
Coating quality and lubrication
Wire cast (how well the wire flows off the spool)

Surface Condition & Tensile: The most common issue affecting wire surface condition and roundness of the wire is the quality of the drawing dies and how well the drawing process is maintained. The die is just like any other knife. When dull, it will scar the surface. Dull drawing dies also will heat up the wire, changing its properties and causing uneven tensile throughout the spool of wire.

Coating & Lubrication: Zinc-coated wire, also known as galvanized wire, is the most common type of wire used in saddlestitching today. There still are some companies using tin-coated wire, but it is expensive and does not provide any measurable benefits over a high-quality galvanized product. Stainless steel is another option. Stainless wire should be considered if the end product will be in an environment where the wire is exposed to extreme conditions or because of industry requirements. Medical, food, and pharmaceutical packaging are included in this area.

The corrosion resistance coating on wire is a critical component of wire performance. If the coating is too thick or and has an uneven thickness, it can cause flaking. This is a common problem with low-quality wire. This increases wear and tear on the stitching head components and leads to higher maintenance cost. In manufacturing electroplated wire, the zinc bath must be maintained and checked on every wire lot. If the zinc bath is out of its normal operation parameters, it must be adjusted to avoid poor coating conditions. If a binder is experiencing flaking issues or a buildup of zinc dust on the stitching heads, a premium wire product can eliminate these issues and save money.

A high quality wire will be pre-lubricated during the manufacturing process with a very light coating of oil on the surface. This lubrication is actually absorbed by the wire, giving it a super smooth surface. The application of this coating is critical and ensures performance of the wire as it de-spools and travels through the head. A high quality wire has a proper amount of lubrication to increase line speed and eliminate the adhesion of zinc dust to head parts. In many cases, a low quality wire will have too much or no oil. Too much oil can be as bad as not enough, causing the heads to gum up and slowing production reduce run speeds.

Wire Cast & Spooling: Wire cast refers to how smoothly and evenly the wire flows off the spool. When spooled properly, wire should have a large cast (more than 1.5 times the diameter of the spool) when the wire is allowed to run free on a flat surface. The wire also should lay flat and not tangle or twist.

Wire cast can vary greatly from each spool size. Five pound spools typically have smaller cast than a 35 pound spool. The advantages of a large spool are apparent in the wire cast, but some flexibility is lost with large spools. For medium (5000-9,000 per hour) speed applications, DWT recommends using a 35lb or 200lb spool. The 35 and 200 pound spools have a large inner core that provides a substantial de-spooling advantage over 40lb and 70lb spools.

Stitching wire issues are not always obvious. Sometimes, they appear to be mechanical issues or even operator issues. Before spending money on new stitching heads or reprimanding operators, it’s always a good idea to take a hard look at the stitching wire being used.

Will Spending a Little More on a High-Quality Wire Help My Process?

Using a premium stitching wire can dramatically help improve the throughput process (the number of product produced in eight hours divided by 8). As a gauge, the throughput should be 80 percent or higher of the mechanical speed of the stitching line. Once the machine is running, it should run non-stop until the operator shuts it off. The printed product is seldom the cause of a shut down. If a binder is experiencing low throughput on a stitching line, eliminate one very large variable – low-quality wire. A high-quality wire will reduce down time, reduce head maintenance, reduce operator frustration, increase throughput and increase the profitability of the binding operation.

Companies using high-quality wire on well maintained stitching lines will win more orders. Investing in high-quality wire reduces the cost per stitch, allows the binder to produce a more accurate quote and puts more money on the bottom line.

Harry Lewis is product manager, stitching wire for Dorstener Wire Tech, located in Spring, TX. For more information, call 281-651-6226 or visit www.dwt-inc.com.

Saddlestitching Technologies Save Time and Money

February 1, 2008

by: Renée Varella

Binderies look to reduce production costs through automation and other innovations that offer quick set-ups and changeovers. Here’s an overview of saddlestitching technologies and equipment upgrades from five companies, all designed to enhance efficiencies – and profits.

Automation Options

Automation and other technologies in the saddlestitching process can save set-up time, help binderies use materials more efficiently, and reduce the number of operators required to do a job. For example, Standard Horizon’s automated StitchLiner 5500 gathers flat 4-page signatures, scores, plow-folds, and then drops the sheets onto a saddle for stitching. A single operator can run the machine, which features large, icon-based color touchscreens, prompting the operator through all set-up steps. The operator selects the graphically-represented finishing style, inputs sheet dimensions and other parameters, and then stepper-motors drive all of the substations to the correct settings. The commercial-duty system can handle up to 50 physical sheets (200-page booklets); job changeovers can be completed in three minutes or less.

“The process has another advantage, too,” said Mark Hunt, director of marketing for Standard Finishing Systems. “With conventional saddlestitching, parent sheets are printed 8- or 16-up and then signature-folded, but booklet production cannot start until all of the signatures have been prepared. With the StitchLiner, production can start immediately after printing, allowing partial deliveries or a jump-start on the next downstream process, such as mailing and inserting.”

Heidelberg’s Stitchmaster ST 450, for mostly short-run jobs, offers advanced automation features, quick make-ready, and fast changeover. A touchscreen controls automatic synchronization of machine aggregates and automatic format presetting for feeders, trimmer, and compensating stacker. The ST 450 runs at speeds up to 14,000 cycles per hour.

With the Stitchmaster ST 450, an operator can configure as many as 32 pockets to the specific requirements of any job. Pockets can be moved easily and placed anywhere on either side of the saddle chain, automatically synchronizing to the chain based on the format and the cycle speed. When coupled with the independent servo-motor drive, which helps send electronic job tickets for automatic presetting, these features create flexibility and automation for any type of stitching job. Servo-motors and stepping-motors eliminate the need for moving of guides by hand – creating a faster, synchronized makeready time.

Heidelberg’s ST 350, which runs at 12,000 cycles per hour, offers a semi-automated solution for work that tends to keep the stitching line in continuous from small- to high-volume operation. The central graphical touchscreen and controls on every unit enable automatic synchronization of the saddle chain with feeders and the stitcher. Heidelberg’s ST 90 and ST 100 models, for small- to medium-volume production, run up to 9,000 cycles per hour, with easy changeover and operation. Both models allow a printer to keep jobs in-house for complete finishing.

Vijuk Equipment’s 321-T saddlestitcher automatically feeds and gathers signatures through its independently-driven horizontal feeders. The in-line cover feeder/folder offers regulated air blasts for dependable feeding, and on-the-fly adjustment for cover alignment and scoring. The 321-T also offers high-quality control with missing- , double- , and dropped-signature detection in each feeder, in addition to an oblique monitor for signature registration, an over/under caliper, and missing-stitch detection.

“The 321-T stitcher offers an optional programmable, in-line, digital, variable-data ink-jetting system with dual print heads that simultaneously ink-jets the outside and inside of booklets,” said Kevin Boivin, sales coordinator for Vijuk Equipment. “An in-line multi-purpose trimmer that performs perimeter diecutting, interior diecutting, hole punching, perforating, and trimming of booklets in 1- to 3-up formats can be attached.” The CE-certified machine is rated at 10,000 cycles per hour, and 2-up production is available.

Other Innovations

New stitching technology can be found in the MBM Corporation’s StitchFold bookletmaker, an ISP wire-fed stitching system that offers lower operating costs than systems using pre-formed staples. The StitchFold can produce booklets up to 100 pages, and jogs, stitches, and folds up to 65,000 booklets without the need to replace the wire spools. Magnetic stitching heads feature one-step threading for quick and easy set-up, and the knife fold with dual-fold rollers provides crisp, consistent folds.

The Deluxe Stitcher Company manufactures a range of freestanding machines, stitcher heads, and replacement component parts for nearly all makes and models of stitcher machines and heads. Multiple-head machines include the pamphlet-making M17 Stitcher, the versatile M27 pad stitcher, and the Behemoth 18AW that takes up to 10 heads. Deluxe multi-head stitchers are designed to increase productivity with the ability to put in as many as 10 stitches in one cycle.

Cost Savings for Customers

In addition to wanting features that simplify production, binderies aim to reduce customers’ costs. Heidelberg’s Stitchmaster equipment can save time and effort in the final phase of a job, where delays in prepress and printing often have to be made up. Digital controls and sophisticated technology help Stitchmaster operators avoid post press “bottlenecks” and higher productivity in the bindery means high-quality jobs are finished in less time.

“Customers using Standard Horizon’s automated saddlestitching systems can efficiently process short-run jobs with lower set-up labor costs v. conventional saddlebinding lines, Hunt said. Operators input job parameters on the color touchscreen, then precision stepper-motors drive all sub-systems – such as side guides, end stops, stitching heads, and trimming knives – to the correct position in minutes. “Automated systems also have a great deal of the set-up intelligence ‘built-in,’ so customers can rely less on specialized operator skill,” he said.

“One trade binder decided to put our ‘easy-to-operate’ claims to the test, and pulled an employee from shipping and receiving to run our system,” Hunt added. “That employee was subsequently promoted and is still running the StitchLiner, overseeing several million booklets through the system. Trade binders with the right automated equipment now can compete effectively and make money on short-run work that they used to turn away.”

Boivin notes that Vijuk’s 321-T offers many of the top mechanical features of comparable computerized saddlestitchers, including a flying stitching-head system and Hohner stitching heads, allowing operations of any size to upgrade their binding capabilities. “The 321-T is designed and priced for printers who cannot justify computerized automation and highly skilled labor,” he said. “Our customers cite labor savings because of how quickly employees can be trained to operate the system. With the 321-T’s comprehensive quality-control features, customers realize material savings almost immediately.”

Competition is fierce. and profit margins are tight. The efficiencies gained with the latest technologies in saddlestitching equipment can make the difference for binders looking for an edge.

Our thanks to the following companies for contributing information to this article: Deluxe Stitcher Company, (800) 634-0810, www.deluxebostitch.com; Heidelberg, (888) 472-9655, www.us.heidelberg.com,; MBM Corporation, (800) 223-2508, www.mbmcorp.com; Standard Horizon, (877) 404-4460, www.sdmc.com; and Vijuk Equipment, (630) 530-2203, www.vijukequip.com.