Binding
Binding
Binding
Horizon Perfect Binders
Horizon Perfect Binders
For perfect bound booklets, we use our BQ 480 and BQ470 Horizon Perfect Binders. The BQ 480 is the more advanced model but both machines have several automated features to reduce make-ready times. No matter how thick a booklet is, these machines will adjust various features to ensure a strong bind is created – from the depth of glue penetration to how much glue is applied.
Our perfect binders are positioned within our factory for optimal efficiency. The majority of our booklets are printed on one of our two Truepresses so the binders are placed near-line to them. After binding, our Horizon Variable Trimmer HT 1000V is attached inline to take bound booklets and trim off the excess.
Horizon StitchLiners
Horizon StitchLiners
With four StitchLiner Mark IIIs and two StitchLiner 5500, we have quite a formidable saddle-stitching department. Both excellent machines, the Mark III offers a more automated process as operators can program all modules at once before setting the job in motion.
All StitchLiners start with their collation towers, feeding in 4-page sections. These pages are then knocked up in the accumulator before being stitched. Finally, stitched booklets are passed into the three-knife trimmer which cuts off the excess on all three exposed sides at once.
Renz Desk Punch Wiro
Renz Desk Punch Wiro
When we first explored the possibilities of wiro-binding, this was the machine we bought to punch holes into the spine of your booklets. The die pattern can be manually adjusted for booklets or calendars and dependant on the product size.
The Desk Punch is a very manual process; operators must hold stacks of paper under the die and press a foot pedal down to make each punch. This is manageable while demand is low but as more customers ordered wiro-bound booklets and calendars, we knew we had to expand our department.
Renz AP360 Punch Wiro
Renz AP360 Punch Wiro
After offering wiro-bound booklets and calendars for a little while, we knew we had to find a more efficient process to punch holes than the Renz Desk Punch could give us. So we bought the Renz AP360 which offers a more automated approach.
Pre-collated and trimmed pages for multiple jobs can be loaded into the Renz AP360 at once. The die is adjusted to the correct size (and pattern for calendars or notebooks) and then pages are fed through to be punched.
Renz MOBI 500 Wiro Binder
Renz MOBI 500 Wiro Binder
The MOBI 500 was the first wiro binder we bought when we first started offering wiro-bound booklets and calendars. Like the Renz Desk Punch, this is a very manual piece of equipment.
Operators hook the pre-punched pages onto the wire coil and press a foot pedal to pinch the wire closed. If the product is a calendar, operators must also drop in the calendar hanger before the wire is closed.
Renz ABL 500 Wiro Binder
Renz ABL 500 Wiro Binder
As demand for wiro-bound booklets and calendars grew, we knew that we needed to expand our wiro-binding operations. The more automated ABL 500 meant that we could increase our capacity to meet demand. Now, operators need only place the collated pages on the machine and it will automatically thread wire through the punched holes and add a calendar hanger in if necessary.
Kolbus KM600 Binding Line
Kolbus KM600 Binding Line
Our state-of-the-art Kolbus KM 600 is coupled with a ZU 832 gathering machine and HD 143.P three-knife trimmer to form a streamlined process. We carefully collate pages using our ZU 832 gathering machine ensuring the books are in the correct order ready to be bound.
The Kolbus KM 600 applies adhesive, mills, and notches the spine, guaranteeing a flawless book block bound. We’re proud that we only use Planamelt adhesive for its high quality, ensuring a fault-free and superior spine. This cost-effective adhesive demonstrates remarkable resilience to both high and low temperatures, requiring only minimal application compared to EVA adhesive.
The final touch comes from the HD 143.P Three-Knife Trimmer, our expert trimmer ensures each book is sized and trimmed to perfection before making its way to the conveyor belt, ready to be securely packaged and dispatched.
Kissun DB440 K-Binding Machines
Kissun DB440 K-Binding Machines
Our layflat manufacturing process utilises the Kisun DB440, a dual feeding system that applies adhesive to the paper sheets.
The special adhesive we use for our layflat books is Alfast 654, which bonds all pages. After all pages have been securely bonded, our operatives will position the book block into the compressor, ensuring the book is of the highest quality.
Muller Martini 3215 Ventura MC200 Section Sewing Machine
Muller Martini 3215 Ventura MC200 Section Sewing Machine
We utilise our two Muller Martini Ventura MC200 machines for thread-sewn book production. The sewing process involves utilising blow air and an active thread cutting system.
We first punch the holes in the paper, then sewing needles pull the thread through alternate holes with a burst of air, forming a loop in the slotted lever. The hook needles then catch the loop, and both the hook needle and sewing needle simultaneously pull the thread up, resulting in the creation of a thread chain.
The thread-sewn sections then progress to the Kolbus KM600, where the book's cover is glued to the spine using Kleiberit 743.7 EVA adhesive.