The increasing degree of automation is the two distinctive features of the modern binding industry, and wireless binding is no exception. Partly due to the need for on-demand printing drivers, partly due to lower worker skills, commercial printing plants have to maintain a competitive cycle to meet customers' expectations for delivery time and quality, and are using increasingly automated wireless binding. equipment.
In addition, tighter job turnaround times and the need to increase control over all aspects of production have also prompted commercial printers to expand their internal wireless binding capabilities.
In the absence of skilled workers since the mid-1980s, there were few automatic devices in the bookbinding industry. However, in the past 15 years, the regulation of machines has become more and more automated, so that qualified operators can produce fewer products with qualified machine time if they are not skilled enough.
The development of automated and digitally controlled devices frees all important adjustments from human factors. This is particularly critical for three-shift operations because each operator has his or her own idea of ​​what to do, and this will cause problems. This inconsistency can cause serious problems in terms of efficiency, productivity, and quality.
Instead of leading the operative's craftsmanship and knowledge, more intelligence is given to the machine. It is increasingly difficult to attract talented technicians into the printing industry, especially the bookbinding industry.
Programmable Logic Control Reduces Operational Errors The Quadrimax four-binder bookbinding machine of Duplo, California, does not require any adjustment by the operator. When a job is finished, the operator does not need to do anything for a different size of work--the machine automatically adjusts. This automatic adjustment makes Quadrimax suitable for high-quality, on-demand binding tasks. Rated speed is 1,000 books per hour. It can both bind books with only 2 pages and can also bind books up to 1.8 inches thick.
However, the automation effort in wireless binding is a double-edged sword. The customer welcomes the benefits of computerization and fears that the operatives will not be able to adapt. In this regard, Miller Martini proposed several solutions to help customers to help operator training. The programme includes computer-based training for customers in their own factories and a series of trainings in Miller Martini, suitable for junior technicians and senior technicians.
At Miller Martini's Acoro and Corona wireless binder's computer console, the operator can easily complete the tuning tasks by entering the parameters of the bound book. The servo motor controlled by the Commander console on the Acoro automates 35 adjustments related to the book. It takes less than 5 minutes to replace one job. In the past, wireless half-set adjustments depended on speculation and are now different. Computer programming logic does not allow blind operators to operate.
Acoro is rated at 5,000 rpm, while Corona offers configurations ranging from 1.2 to 18,000 rpm. For small batches, there is a separate Amigo wireless binder (1500 rpm); for online binding, Tigra (3,600 rpm).
Another technique used by Miller Martini for wireless binders is "ASIR: Automatic Signature Image Recognition". This is a video chip camera. It observes the signature to determine if the signature is in the correct position and is in the correct signature.
In addition, individual defective books can be automatically removed by installing a reject gate between the collation machine and the binding machine. This defective door can also be programmed. The preselection takes into account a single defective product caused by the wrong page and automatically staples the machine after a specified number of consecutive defective products.
Single-binder binding machines also reflect the need for ease of operation and faster turndown times. Rosback's 880 wireless binder in Michigan, USA, now has Programmable Logic Control (PLP) that can guide operators through the entire process, making the tuning machine faster and the novice easier to operate.
Increasing productivity “Times†In order to increase productivity, the company has been researching and developing a new method of binding magazines for the same post-processing equipment manufacturer and Quad/Graphics printing plant over the years. This device, called MagnaBinder, is designed to produce flat ridges at 40,000 copies per hour. Fifteen months ago, a prototype had been placed in the Quad/Graphics facility in Wisconsin and is now being fine-tuned. Although printing now uses very light paper and some special inserts, the overall productivity of such binding machines is still high. The production speed of the current saddle stitcher should be 18,000 volumes per hour. Depending on the complexity of the magazine and the weight of the paper stock, 6000-12000 books can be bound per hour on the MagnaBinder. Although not reaching the design speed of 40,000 volumes per hour, 20,000 volumes can still be achieved.
The increase in automation is also aimed at meeting the need to increase productivity and reduce the rate of depletion as print volumes continue to decline. Everyone is looking for high-yield, low-maintenance, and quick-change job solutions, especially in the middle range of binding machines. Printers want to be able to switch from one job to another within a short period of time.
Last fall, Mann Rolland signed an agreement to represent Wohlenberg's wireless binder in North America and its range of three-sided knife cutters and cutters. The Warren Bros. wireless binding machine may be unfamiliar in North America, but it is very popular in Europe and Japan, and may be the most sought-after in the market.
The Warrenberg company produces a range of medium-range wireless binders, ranging from fully manual to full-automatic, capable of binding 4000-8,000 volumes per hour. The Champion E can prepare 28 to 30 signature posts from a remote station within 5 minutes.
High Speed ​​Paper Handling In addition to the automation of the bookbinding machine itself, equipment manufacturers are also trying to increase the speed of paper handling. For example, KOLBUS has launched the ZU840 collating machine as part of their Publica equipment line for magazine and catalog printing production services.
The traditional page matching process on the wireless binder machine is a crossrotary collator that draws a signature from a spinner's signature bin and puts it on track. However, this requires changing the direction of the product. Instead of rotating rollers, KOLBUS's new collating machine uses a shuttle-type belt feeding system to send signatures directly to the product flow path.
When dealing with paper in high traffic, any change of direction can cause problems. By eliminating the need to change direction, many of the problems often encountered in wireless binding are eliminated, particularly the problems that are often encountered with very thin and thin paper stocks and two-page signatures.
Another growing challenge facing the special binding industry, the wireless binding industry, is the increasing use of special gimicks in publications. In previous magazines, occasionally a card was inserted, but now more and more bound to the disc, 3in.x5in. card and full sheet of paper.
A customer's publication contained so many special inserts that the printer had to put in order before binding. Because the printing plant's equipment does not have so many bookbindings to bind all things at once.
The increase in special inserts directly reduces the possibility of increasing the productivity of wireless binding jobs. Therefore, equipment manufacturers like Heidelberg have studied how to increase efficiency. While maintaining the integrity of the wireless binding, they consider how to make the feeding device both able to hold traditional signatures and other inserts. This research method includes the whole process of wireless binding from feeding to light. The bound surface is now not only flat, square, but often has an irregular surface, they will affect the light edge process. In order to improve the logistics of irregular objects, the equipment must be designed so that it can avoid hanging angles, so that it can smoothly move from one process to another.
Equipment manufacturers must also consider ways to improve spine preparation. One factor that influences those changes is the major changes in the paper materials. Compared with 5 years ago, lightweight paper and coated paper are used much more. Since the cut-off at the roughage station depends on the material being processed, Heidelberg aims to help the binder to provide the best overall quality without having to change different ones when replacing different jobs. head.
The current trend in market demand is that many commercial printers are vying for wireless binding equipment. This is because the print batch size is getting smaller and the delivery time is getting tighter. The control of a batch of printing tasks should be in their own hands, and they cannot rely on or ask for others.
Heidelberg's BindExpert "binding specialist" is suitable for small print shops. However, some large plants are also purchased to handle some special requirements. For example, if a customer has a business of 1 million, but he first needs 40-50 samples, the printer can first do it on a small wireless binder without having to activate a large wireless binder.
A Spiel Associates company in Long Island, New York, USA produced a Sterling Minibinder "microbinder". This is a single-page bookbinding machine that can bind 600 books per hour and adjust the time for about 10 minutes. With a nipping motor, you don't need to indent most of the cover. The company's design philosophy is that wireless binding operations should be as simple as possible. Although this micro bookbinding machine does not have key automation, everything it needs to produce a high-quality book includes a complete milling, slotting and sanding station with a carbide blade, and an attachment to the side of the spine. , used to make a cover reinforced with a cloth strip.
GBC, an American company in Illinois, launched their PF3200 wireless semi-customer at the recent On Demand Show. Its main features are the operator-controlled clamping time and a slotting device that is said to eliminate paper dust. The machine's automatic clamping device can adjust instantly according to the thickness of the book. In this way, adjustments can be made without one job and one job. Its double channel grooving device allows better penetration of glue.
Wireless binder machines from Brackett, Inc., Topeka, Kansas, USA, are suitable for small-volume printers. They can be used in multiple applications: wireless binding or bookbinding. The two models recently produced by the company are: I-binder and I-binder II. The rated speed is 80-120 books per hour and 480 sheets of paper, 0.25 inches thick. The I-binder bookbinding machine can handle books up to 1 inch in size; the I-binder II bookbinding machine can handle books up to 1.5 inches in thickness.
Note the spine preparation For optimal bonding, a good quality upper coater will remove the spine approximately 0.125-0.1875 inches when milling and sanding the spine. When non-coated paper is bound, the security blade may be sufficient for slitting. But for ink-coated coated papers, skipping spine preparation would not work. Planak binder and Ribler Gmbh's Rc-1, two binders with cold latex binders, received visitors to Drupa 2000. The favor.
Although wireless binders have been automated, most operators still have to do some troubleshooting. The first reason for analyzing the quality of wireless binding was the operator’s misjudgment.
The adhesive binding reactive polyurethane (PUR=polyurethane reactive) or reactive polyurethane for wireless binding uses this type of adhesive, and the tear rate of the paper is very low. Bonded very firmly. This kind of adhesive is very competitive, and the binder factory that uses this kind of adhesive has access to the business. In the past, this type of adhesive was used primarily for hard-to-find products such as high-grade coated paper or books subject to extreme temperatures. It is now much more widely used.
Reactive polyurethanes require different equipment and different usage. As printers become more familiar with the equipment and improve their skills, they are also more willing to use this type of reactive polyurethane where they originally used hot melt adhesives.
There are two reasons to like to use reactive polyurethanes: first, it is designed specifically for coated paper; second, it is used to glue books, and the book will never be dispersed. Another advantage is that active polyurethane is harmless to the environment, and books bound with it are easier to recycle.
The reason why more and more active polyurethane and paper are used today. Faced Paper Filler
In addition, tighter job turnaround times and the need to increase control over all aspects of production have also prompted commercial printers to expand their internal wireless binding capabilities.
In the absence of skilled workers since the mid-1980s, there were few automatic devices in the bookbinding industry. However, in the past 15 years, the regulation of machines has become more and more automated, so that qualified operators can produce fewer products with qualified machine time if they are not skilled enough.
The development of automated and digitally controlled devices frees all important adjustments from human factors. This is particularly critical for three-shift operations because each operator has his or her own idea of ​​what to do, and this will cause problems. This inconsistency can cause serious problems in terms of efficiency, productivity, and quality.
Instead of leading the operative's craftsmanship and knowledge, more intelligence is given to the machine. It is increasingly difficult to attract talented technicians into the printing industry, especially the bookbinding industry.
Programmable Logic Control Reduces Operational Errors The Quadrimax four-binder bookbinding machine of Duplo, California, does not require any adjustment by the operator. When a job is finished, the operator does not need to do anything for a different size of work--the machine automatically adjusts. This automatic adjustment makes Quadrimax suitable for high-quality, on-demand binding tasks. Rated speed is 1,000 books per hour. It can both bind books with only 2 pages and can also bind books up to 1.8 inches thick.
However, the automation effort in wireless binding is a double-edged sword. The customer welcomes the benefits of computerization and fears that the operatives will not be able to adapt. In this regard, Miller Martini proposed several solutions to help customers to help operator training. The programme includes computer-based training for customers in their own factories and a series of trainings in Miller Martini, suitable for junior technicians and senior technicians.
At Miller Martini's Acoro and Corona wireless binder's computer console, the operator can easily complete the tuning tasks by entering the parameters of the bound book. The servo motor controlled by the Commander console on the Acoro automates 35 adjustments related to the book. It takes less than 5 minutes to replace one job. In the past, wireless half-set adjustments depended on speculation and are now different. Computer programming logic does not allow blind operators to operate.
Acoro is rated at 5,000 rpm, while Corona offers configurations ranging from 1.2 to 18,000 rpm. For small batches, there is a separate Amigo wireless binder (1500 rpm); for online binding, Tigra (3,600 rpm).
Another technique used by Miller Martini for wireless binders is "ASIR: Automatic Signature Image Recognition". This is a video chip camera. It observes the signature to determine if the signature is in the correct position and is in the correct signature.
In addition, individual defective books can be automatically removed by installing a reject gate between the collation machine and the binding machine. This defective door can also be programmed. The preselection takes into account a single defective product caused by the wrong page and automatically staples the machine after a specified number of consecutive defective products.
Single-binder binding machines also reflect the need for ease of operation and faster turndown times. Rosback's 880 wireless binder in Michigan, USA, now has Programmable Logic Control (PLP) that can guide operators through the entire process, making the tuning machine faster and the novice easier to operate.
Increasing productivity “Times†In order to increase productivity, the company has been researching and developing a new method of binding magazines for the same post-processing equipment manufacturer and Quad/Graphics printing plant over the years. This device, called MagnaBinder, is designed to produce flat ridges at 40,000 copies per hour. Fifteen months ago, a prototype had been placed in the Quad/Graphics facility in Wisconsin and is now being fine-tuned. Although printing now uses very light paper and some special inserts, the overall productivity of such binding machines is still high. The production speed of the current saddle stitcher should be 18,000 volumes per hour. Depending on the complexity of the magazine and the weight of the paper stock, 6000-12000 books can be bound per hour on the MagnaBinder. Although not reaching the design speed of 40,000 volumes per hour, 20,000 volumes can still be achieved.
The increase in automation is also aimed at meeting the need to increase productivity and reduce the rate of depletion as print volumes continue to decline. Everyone is looking for high-yield, low-maintenance, and quick-change job solutions, especially in the middle range of binding machines. Printers want to be able to switch from one job to another within a short period of time.
Last fall, Mann Rolland signed an agreement to represent Wohlenberg's wireless binder in North America and its range of three-sided knife cutters and cutters. The Warren Bros. wireless binding machine may be unfamiliar in North America, but it is very popular in Europe and Japan, and may be the most sought-after in the market.
The Warrenberg company produces a range of medium-range wireless binders, ranging from fully manual to full-automatic, capable of binding 4000-8,000 volumes per hour. The Champion E can prepare 28 to 30 signature posts from a remote station within 5 minutes.
High Speed ​​Paper Handling In addition to the automation of the bookbinding machine itself, equipment manufacturers are also trying to increase the speed of paper handling. For example, KOLBUS has launched the ZU840 collating machine as part of their Publica equipment line for magazine and catalog printing production services.
The traditional page matching process on the wireless binder machine is a crossrotary collator that draws a signature from a spinner's signature bin and puts it on track. However, this requires changing the direction of the product. Instead of rotating rollers, KOLBUS's new collating machine uses a shuttle-type belt feeding system to send signatures directly to the product flow path.
When dealing with paper in high traffic, any change of direction can cause problems. By eliminating the need to change direction, many of the problems often encountered in wireless binding are eliminated, particularly the problems that are often encountered with very thin and thin paper stocks and two-page signatures.
Another growing challenge facing the special binding industry, the wireless binding industry, is the increasing use of special gimicks in publications. In previous magazines, occasionally a card was inserted, but now more and more bound to the disc, 3in.x5in. card and full sheet of paper.
A customer's publication contained so many special inserts that the printer had to put in order before binding. Because the printing plant's equipment does not have so many bookbindings to bind all things at once.
The increase in special inserts directly reduces the possibility of increasing the productivity of wireless binding jobs. Therefore, equipment manufacturers like Heidelberg have studied how to increase efficiency. While maintaining the integrity of the wireless binding, they consider how to make the feeding device both able to hold traditional signatures and other inserts. This research method includes the whole process of wireless binding from feeding to light. The bound surface is now not only flat, square, but often has an irregular surface, they will affect the light edge process. In order to improve the logistics of irregular objects, the equipment must be designed so that it can avoid hanging angles, so that it can smoothly move from one process to another.
Equipment manufacturers must also consider ways to improve spine preparation. One factor that influences those changes is the major changes in the paper materials. Compared with 5 years ago, lightweight paper and coated paper are used much more. Since the cut-off at the roughage station depends on the material being processed, Heidelberg aims to help the binder to provide the best overall quality without having to change different ones when replacing different jobs. head.
The current trend in market demand is that many commercial printers are vying for wireless binding equipment. This is because the print batch size is getting smaller and the delivery time is getting tighter. The control of a batch of printing tasks should be in their own hands, and they cannot rely on or ask for others.
Heidelberg's BindExpert "binding specialist" is suitable for small print shops. However, some large plants are also purchased to handle some special requirements. For example, if a customer has a business of 1 million, but he first needs 40-50 samples, the printer can first do it on a small wireless binder without having to activate a large wireless binder.
A Spiel Associates company in Long Island, New York, USA produced a Sterling Minibinder "microbinder". This is a single-page bookbinding machine that can bind 600 books per hour and adjust the time for about 10 minutes. With a nipping motor, you don't need to indent most of the cover. The company's design philosophy is that wireless binding operations should be as simple as possible. Although this micro bookbinding machine does not have key automation, everything it needs to produce a high-quality book includes a complete milling, slotting and sanding station with a carbide blade, and an attachment to the side of the spine. , used to make a cover reinforced with a cloth strip.
GBC, an American company in Illinois, launched their PF3200 wireless semi-customer at the recent On Demand Show. Its main features are the operator-controlled clamping time and a slotting device that is said to eliminate paper dust. The machine's automatic clamping device can adjust instantly according to the thickness of the book. In this way, adjustments can be made without one job and one job. Its double channel grooving device allows better penetration of glue.
Wireless binder machines from Brackett, Inc., Topeka, Kansas, USA, are suitable for small-volume printers. They can be used in multiple applications: wireless binding or bookbinding. The two models recently produced by the company are: I-binder and I-binder II. The rated speed is 80-120 books per hour and 480 sheets of paper, 0.25 inches thick. The I-binder bookbinding machine can handle books up to 1 inch in size; the I-binder II bookbinding machine can handle books up to 1.5 inches in thickness.
Note the spine preparation For optimal bonding, a good quality upper coater will remove the spine approximately 0.125-0.1875 inches when milling and sanding the spine. When non-coated paper is bound, the security blade may be sufficient for slitting. But for ink-coated coated papers, skipping spine preparation would not work. Planak binder and Ribler Gmbh's Rc-1, two binders with cold latex binders, received visitors to Drupa 2000. The favor.
Although wireless binders have been automated, most operators still have to do some troubleshooting. The first reason for analyzing the quality of wireless binding was the operator’s misjudgment.
The adhesive binding reactive polyurethane (PUR=polyurethane reactive) or reactive polyurethane for wireless binding uses this type of adhesive, and the tear rate of the paper is very low. Bonded very firmly. This kind of adhesive is very competitive, and the binder factory that uses this kind of adhesive has access to the business. In the past, this type of adhesive was used primarily for hard-to-find products such as high-grade coated paper or books subject to extreme temperatures. It is now much more widely used.
Reactive polyurethanes require different equipment and different usage. As printers become more familiar with the equipment and improve their skills, they are also more willing to use this type of reactive polyurethane where they originally used hot melt adhesives.
There are two reasons to like to use reactive polyurethanes: first, it is designed specifically for coated paper; second, it is used to glue books, and the book will never be dispersed. Another advantage is that active polyurethane is harmless to the environment, and books bound with it are easier to recycle.
The reason why more and more active polyurethane and paper are used today. Faced Paper Filler
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