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BINDERY matters

May 2005
Show Shines for Manufacturers

ORLANDO—With 150 exhibit spaces of machines and services at Orlando Graphics 2005, held in April, enthusiasm for 2006 has already been expressed with 98 percent commitment by this year's exhibitors.

"The quality of visitors, not the quantity, is what generates business for us," says Hans Max, president and CEO of MBO America, an exhibitor at the show. "We were extremely satisfied not only with the immediate sales, but the followup sales and leads produced by Orlando Graphics."

MBO ran demonstrations allowing visitors to see more than 20 multiple-machine configurations bringing improved production to the pressroom or bindery. There was excitement over MBO's fully automated Perfection folder and automatic electronic setup/support system, Rapidset, throughout the entire folder. MBO's new easy-access slitter shaft cassette, available as an option on a Perfection folder, was also displayed.

Also during the event, Muller Martini showcased its Presto saddlestitcher, which was connected to a Palamides Delta 502 banding machine. Muller also demonstrated—all-in-line—its AmigoPlus perfect binding system, SigmaTower cooling station and Esprit three-knife trimmer.

"I'm certain that many Orlando Graphics show visitors came away from our booth having gained valuable insights and creative ideas about how they can make their operations more competitive while also expanding their service offerings and profit potential," notes Werner Naegeli, president and CEO of Muller Martini.

Another exhibitor, Colter & Peterson, displayed a 45˝ Wohlenberg cutter, a 37˝ Saber cutter, a Baumann jogger and a full range of Microcut control systems.

"Because Orlando Graphics was much smaller than a Graph Expo or PRINT show, it gave visitors a very good opportunity to see equipment in a relaxed atmosphere and to get more one-on-one attention from the exhibitors," adds Jeff Marr, vice president of sales at Colter & Peterson.

"But, for its size, there was still quite a bit of equipment on display," he contends. "In fact, one guy commented to me that if he'd known beforehand just how good it really was, he would have brought more people from his shop with him."

This Installation Literally Is One For the Books

YORK, PA—The Maple-Vail Book Manufacturing Group wanted to automate the process of removing stacks of unfinished books from one machine and placing them onto a pallet. The existing process required two workers on each of three shifts at a cost of $120,000 annually. While robotic palletizing is becoming commonplace, designing an end-effector to complete the process was more complicated.

"In book manufacturing, getting the end-effector right is the key," says Scott Simons, vice president of operations for Maple Press. "This equipment must perform multiple, precise functions, so it usually must be custom-designed."

Pages for each book are printed and bound, then stacked with other books by an automated stacking machine, which created 6˝ to 13˝ stacks. The stacks were then palletized by hand. To automate the palletizing process, Maple Press selected equipment from Westfalia Technologies .

Westfalia's robotic palletizer handles 16 stacks per minute, picking up two or three stacks at a time. The company's end-effector allows a range of stack sizes to be picked up and presented to the robot in a row. The end-effector then extends an adjustable fork assembly that can support a 36˝ long row of books, which is held in place by a pneumatically controlled pressure plate.

Books are then moved into position and placed onto the pallet by retracting the forks. The height of each layer is individually measured by a laser, which provides precise height adjustments for the robot as it drops each layer into place.

Trade Shop Upgrades Its PUR Capabilities

WOBURN, MA—At Seaboard Bindery, the company has upgraded its PUR (polyurethane reactive) binding capabilities with the installation of a Nordson binding system. The machine features an even distribution of glue over a defined area, greatly reducing makeready, production and wasted glue during perfect binding production.

Using the computerized glue controller on the Nordson system, Seaboard Bindery can determine the precise amount and location of PUR glue to be applied. During binding, the system uses an electric eye that senses the book and triggers the glue application device. Glue is then applied to the product.

According to Frank Shear, president of Seaboard Bindery, the Nordson system will allow Seaboard expanded perfect binding production capability.

"We can now provide the benefits of PUR glue to high-end binding 100 percent of the time," he notes. "Makeready and job runs will be faster, and imposition requirements will not be as stringent."

quick cuts

Big D Bindery in Dallas has installed a Muller Martini Corona C12 perfect binder. Pictured from the left are Big D employees Buel Crawford, John McGee and Joe White with the newest addition to the shop.

Gane Brothers & Lane in Elk Grove Village, IL now has the ability to furnish high- or low-density coverboard in virtually any size after installing two board cutting machines. Its Kolbus PK-PK 170, reportedly the largest machine of its kind in North America, features microprocessor controls and feeds up to 60 sheets per minute. The smaller of the two systems is a Crawley cutter, used for quick turnaround of smaller volume orders.

Winthrop Printing, located in Boston, reports a 25 percent increase in production with the recent installation of a jogger, a Transomat and a Polar cutter from Heidelberg. Currently, the shop is using the equipment to finish brochures, direct mail pieces and pocket folders. With more than 80 years of experience in the printing industry, Winthrop Printing is a family owned and operated general commercial printer.

Appalachian Graphic Finishing, located in Knoxville, TN, chose an EHD series press, recently rebuilt by Brandtjen & Kluge, to add value to its finished products. As an area trade shop, Appalachian will use the new press for foil stamping, embossing and diecutting applications.

Contemporary Graphics has installed a Muller Martini Presto saddlestitcher to join an existing Omni binder at its Pennsauken, NJ, headquarters. The result is a nearly 300 percent jump in production capacity.


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