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“When we buy equipment now, we verify that it’s CIP4-compliant, but we utilize that technology on a limited basis in the bindery,” admits Mike McLaughlin, director of production at Challenge Printing in Shakopee, MN. “Our operators, like many others, can punch a program into a cutter or set up a folder pretty quickly. Though a complete digital workflow from order entry through finishing is intriguing, this technology, like any other, needs to be carefully thought out and measured on its return.”
For some applications, however, digital workflows have changed the way materials are handled in the bindery, adds Tom Benedict, senior vice president of sales and marketing, Banta Catalog Group. One example is accuracy of ink-jet addresses and messages on mailings.
“The Postal Service’s MERLIN system requires the printed barcode to be completely legible, so Banta has implemented its proprietary Banta Vision System, which places barcode readers on the bindery line,” Benedict notes. “The Banta Vision System verifies the accuracy of information and reads every barcode that goes through the machine. If the barcode is not legible, it rejects the product and reorders it in the system. As the only printer with this system, our direct marketing customers can realize savings, efficiency and increased productivity.”
In the immediate future, Banta’s marketing exec sees more marrying of conventional and digitally printed pieces on the binding line. Because of digital workflows, there is an opportunity to digitally produce covers, order forms and selected signatures on the binding line, he says.
“Direct marketers can analyze their customer responses based on data gathering and knowledge and, within hours before binding, are provided opportunities to make smarter decisions regarding product selection and messaging, among other factors.”
Binderies always search for more efficient ways to reduce the tremendous costs associated with materials handling—looking for the shortest distances possible, loading materials with as few motions as possible, and using lifts and other devices to relieve a handler’s dexterity and physical strength, states Werner Rebsamen, professor emeritus at the Rochester Institute of Technology and an expert on the bindery.
“Despite these efforts, materials handling is still perhaps the most costly, labor-intensive task in any print finishing environment,” Rebsamen contends. “During past R&E Council bindery seminars, some speakers have stated that 40 percent of everything (they) do in the bindery is lifting up and stacking down materials.”
Hands-on Area
No matter how automated the graphic arts industry becomes, a great deal of manual handling of materials will remain, Rebsamen believes. “With the exception of in-line systems, (most) materials to be bound come from various sources—on pallets, in boxes, crates, etc. They all must be sorted and moved to the gathering machines. Some of the materials arrive weeks earlier, some at the last minute.”
Because of this, equipment manufacturers are paying closer attention to the safety and ergonomics involved with continuous, long-term materials handling, Challenge Printing’s McLaughlin points out. “Cutting systems can be purchased with turnkey material handling systems for loading and unloading lifts from the cutter bed,” he says. “Portable scissor lifts and permanent in-floor lifts are more common to bring materials to the working level of the operator. Load turner/aerators have become more widely accepted in the industry, and even department layout is given more consideration—all in an effort to reduce injuries and fatigue, as well as to aid throughput.”
As more and more binderies install these labor- and time-saving capabilities, these abilities also increase the importance of the finishing area.
“Binderies will become more of a critical function based on the marketing applications and the ability of digital printing apparatuses to interweave into the binding line,” Banta’s Benedict predicts.
Rebsamen concludes that we are far from seeing the bindery living up to its automation potential. In years to come, more and more companies will move to a more automated process. It’s up to suppliers how far it can go.
“Due to the great variety of work to be processed in print finishing, it is always best to discuss any future investments with your suppliers,” Rebsamen recommends. “It is simply amazing what can be designed and implemented.” PI
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A Field Guide to Folding
Introduction to Graphic Communication
