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9 ideas for better on-demand binding

Mar 1, 2003 12:00 AM, by Frank Shear, President, Seaboard Bindery |

On-demand projects offer different finishing challenges than long-run, high-volume jobs. Quick setup and turnaround times are essential poor planning will severely impact production schedules. Saddlestitching, perfect binding and mechanical binding all have different layout and trim requirements, which may affect how the book is printed. The same is true for other finishing processes, such as folding,

Smarter folding

Feb 1, 2003 12:00 AM, by Samantha Oller, Senior associate editor |

Short runs, faster-turnaround demands and a shrinking supply of skilled bindery professionals have focused printers' folder requirements squarely on quick setup, changeover and makeready. And manufacturers have been quick to respond with systems that provide automated fold setup; storage of previous jobs; adjustment of plates, roller gaps, alignment rails and other components all controlled from a


Jan 1, 2003 12:00 AM,

Service Press was founded by Ralph Laffler in 1963. His son and current president and CEO, Tom Laffler, came on board in 1966 after graduating from Rutgers University. The Metuchen, NJ, printer serves a variety of commercial, industrial and political clients, including Commerce Bank, Prudential Insurance, Johnson & Johnson, Citistreet, Wyeth, Dow Jones, Smith Barney and The New York Times. Early on,


Jan 1, 2003 12:00 AM, By Katherine O'Brien Editor |

The latest on laminators and laminating


Nov 1, 2002 12:00 AM,

NAPL (Paramus, NJ) has published Benchmarking the Bindery, a step-by-step guide to effectively implementing a benchmarking system. Written by Peter Doyle, a printing-company operations manager and benchmarking expert, and Robert Diehl, a company owner and noted speaker, writer and graphic-arts consultant, the volume discusses how to overcome common obstacles to implementing a benchmarking program,


Oct 1, 2002 12:00 AM, BY KATHERINE O'BRIEN Editor |

Inline finishing devices range from pre-folders, plow folders, perforating units, diecutters, slitters, rotary trimmers, inkjet imagers, and imprinting and mechanical numbering devices to gluers and special chemical applicators. Complete systems are offered by Innotech (Valley Cottage, NY), Scheffer Inc. (Merrillville, IN), Western Printing Machinery (WPM) (Schiller Park, IL) and Systems Technology

MATERIALS HANDLING: the bindery's best-kept secret

Sep 1, 2002 12:00 AM, BY GRETCHEN KIRBY PECK Contributing editor |

Materials handling is often an afterthought after a company installs a new press or bindery equipment, jobs start piling up in the bindery because its materials-handling solutions aren't fast enough to keep up. But, some printers don't grasp the wider implications of inefficient materials handling. This is a major activity that adds no value to the product, just additional costs, observe A. John Geis

Avoiding common cutting mistakes

Sep 1, 2002 12:00 AM, by Mark Lee, President, Specialties Bindery |

Some printers try to keep as much work in-house as possible. Do yourself a favor and keep the cutting and binding portions of your jobs together. This will reduce unproductive finger pointing and increase vendor accountability. If printers cut jobs prior to outsourcing other postpress operations, they have by default accepted at least partial responsibility for the overall quality of the project.

Midrange saddlestitchers

Aug 1, 2002 12:00 AM, by Allison McLean, Associate editor |

Users' expectations for midrange saddlestitchers run a wide, sometimes paradoxical, gamut. They need to be speedy, but flexible enough to accommodate a variety of applications and run lengths; they should be easy to make ready, but shouldn't be equipped with cost-prohibitive automation. Fortunately, there are a variety of midrange options that allow printers to select a system best-suited to their

Better bookletmakers

Jul 1, 2002 12:00 AM, by Allison K. McLean, Associate editor |

Bookletmakers are better than ever, largely because yesterday's friction-feed machines have been replaced by today's vacuum suckers. Vacuum suckers don't mark, declares Mark Beard, president of Finishbinders, Inc. (Des Moines, IA), a full-service trade bindery. Printers can run a wide variety of stock on bookletmakers, ranging from carbon paper and carbonless forms to enamel, onionskin and 10-pt.


May 1, 2002 12:00 AM, BY DON PIONTEK Print business manager, ARPAC |

Poly wrapping, or poly bagging, involves wrapping a single sheet of film around a book, magazine or catalog. It usually does not involve shrinking the polyethylene film around the package. (Shrink wrapping refers to wrapping and heat-shrinking products in olefin film.) Protection and postal savings are two key motives for poly bagging a publication. Subscribers expect their magazines to arrive unravaged

Seeking speedy and specialized stitching

Apr 1, 2002 12:00 AM, BY ALLISON K. MCLEAN Associate editor|

At rated speeds of 15,000 cycles per hour (cph) and above, high-speed saddlestitchers are fast and that point should not be understated. Whether the stitching run numbers in the millions, or as low as a couple hundred thousand, the goal is to get it done fast. Ironically, at the 2001 R&E Council bindery seminar, Quad/Graphics (Pewaukee, WI) president and CEO Harry Quadracci noted that maximum speeds

On-demand finishing options

Mar 1, 2002 12:00 AM, BY ALLISON K. MCLEAN Associate editor |

When Xerox introduced the DocuTech in the early 1990s, it created a new kind of printing: on demand. This breakthrough also ushered in new finishing challenges. On-demand finishing obviously must be done quickly but printers can't skimp on accuracy or quality, either. On a variable-data job, each piece is unique; a zero-tolerance waste strategy is a must. And it doesn't matter how fast you can print

Binding hardcover books on demand

Mar 1, 2002 12:00 AM, by Werner Rebsamen, Contributing editor and bindery consultant |

In the mid-1970s, book manufacturers typically stored books for publishers. For example, a major New Jersey book manufacturer had 26 million books in its warehouse mostly Disney and Dr. Seuss titles. Maintaining high inventories was inefficient and costly, but the technology at the time left little choice. There was no computer-controlled or servo-motor-driven hardcover binding equipment. It took

BONUS CUTTER COVERAGE: Avoiding common cutting mistakes

Feb 1, 2002 12:00 AM, By Mark Lee, president, Specialties Bindery

Some printers try to keep as much work in-house as possible. Do yourself a favor and keep the cutting and binding portions of your jobs together. This will reduce unproductive finger-pointing and increase vendor accountability. If printers cut jobs prior to outsourcing other postpress operations, they have by default accepted at least partial responsibility for the overall quality of the project.

Improving the cutting process

Feb 1, 2002 12:00 AM, by Don Piontek, Print business manager, ARPAC |

Cutting is the heart and soul of most printers' production process paper often must be cut before, as well as after, it goes through the press. And printers are constantly cutting stocks to different sizes. But it's labor-intensive depending on the application, the paper may need to be lifted, jogged, aerated, turned and repeatedly moved. Material-handling and cutter upgrades reportedly can yield

A new breed of floor-model folders

Jan 1, 2002 12:00 AM, by Katherine O'Brien, Editor |

There's good folding news and bad folding news. First, the bad news: Paper is still unpredictable. Even famed psychic Madam Cleo couldn't tell you exactly how humidity, inks and sheet-weight variances will impact a specific substrate. Skilled folder operators also remain on the endangered species list. Now the good news: Although floor-model folders still require some manual adjustments, postpress

Folder basics

Jan 1, 2002 12:00 AM, by AP staff |

This article is an online sidebar to "A new breed of floor-model folders," January 2001. There are two basic types of folds and folders. Buckle folders make parallel folds. Often used for leaflets and brochures, a parallel fold involves making two or more folds in a sheet where the folds are oriented in the same direction. Knife folders make right-angle folds. A right-angle fold involves making a

Striving for safety

Oct 1, 2001 12:00 AM, BY A. JAMES OLDEBEKEN President, Printing Industries Assn. of the Heartland (Kansas City, MO) | jim@

According to the U.S. Bureau of Labor Statistics, commercial printing has an injury and illness rate lower than overall manufacturing: five incidents per 100 full-time workers in 1999, compared to 9.2 percent for manufacturing in general. Nonetheless, serious accidents do occur, including loss of eyesight from a chemical splash, or permanent back injury and disability from improper lifting on the

Setting up a fulfillment operation

Sep 1, 2001 12:00 AM, BY A. JOHN GEIS Contributing editor and principal of A.J. Geis Associates (Chapel Hill, NC)

More printers are meeting customer requests to act as order-fulfillment centers, where the printer holds part of a print job and ships the remaining quantity at a later time per the customer's instructions. PIA (Alexandria, VA) reports that in 1999, roughly 30,000 printing companies (out of about 50,000) had fulfillment capabilities. By offering fulfillment services, a printer can be more of a full-service