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At Berryville Graphics, a Milestone in Book Printing

July 1998

With special diverts integrated throughout the system, the accumulators collect the diverted books and refeed them back into the system to keep it continuously running.

"If the binder goes down, the accumulator refeeds the backload into the trimmer," explains Barry Hockenberry, Berryman's director of manufacturing services. "Conversely, if the trimmer goes down, the binder continues to run and accumulate books. The accumulator becomes a buffer area to ensure maximum productivity."

Furthermore, Hockenberry says if Berryville didn't have this buffer in its linked on-line system, the 90-percent efficiency the company is running at now would go down to about 60 percent.

"We're skilled in the disciplines of printing, and that allows us to do the things we dream up," says Taylor. "As with most great inventions, people consider them wacky until they're proven. Such is the case with our three linked in-line systems, the first of which was installed in 1993. A linked in-line bindery operation was just a concept until we proved it to be reality.

"At Berryville, we take an unconventional approach to book manufacturing," continues Taylor. "And that can be challenging in an industry where processes have been done basically the same way for 150 years. By coming up with new innovations, we're trying to convince the industry there's a better way of doing things."

Taylor claims several Berryville competitors have visited the facility, and many are "copying the Berryville approach."

"We figured our competitors would eventually get into the technology," explains Taylor. "But we're the pioneers. We beat the path. Even if others are copying us, we're farther along in the process. They don't have the wisdom and experience that we do, and that comes exclusively from years of hands-on experience."

Berryville produces more than 90 million Duratech-bound books for some of the largest publishing houses in the world, including Thomas Nelson Word, Henry Holt, Farrar Straus & Giroux, Simon & Schuster, Random House, Bantam, Doubleday and Dell.

BY Cheryl A. Adams

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