In the past 20 years, with the rapid development of the world's printing industry, book binding has gradually formed a mechanized, linked, and automated operation process from a backward manual operation process, and the post-press processing equipment is constantly updated. Among them, saddle stitching equipment has gradually developed into a production linkage line with many brands, complete varieties and high degree of automation.
The new modern saddle stitching linkage line is not only suitable for the rapid production of large quantities of jobs, such as the increasing processing of magazines, periodicals, commercial prints, etc. At the same time, it can also achieve a variety of functions, such as arranging posts, inserting inserts and returning mail Cards, binding, automatic three-sided cutting, counting posts and bundling together; in addition, substantial progress has also been made after digital printing in recent years. Next, the author will discuss with you the development and application of the overseas horse-riding linkage line.
Theme: High speed, automatic, digital
1. To the high-speed development, the performance is more stable
The binding speed of more than 10,000 books / hour is no longer difficult for the current saddle stitching linkage line. Many equipment suppliers have demonstrated the high speed characteristics of the equipment, such as Heidelberg company ST350 and ST450, Martini company Supra and Tempo22, Hohner's HSB10000, Osako's Tener, and Gauss' Pacesetter 2500 SPX-25 can all reach speeds above 10,000 books / hour. Among these high-speed models, Martini Supra stands out from the crowd at a high speed of 30,000 copies / hour, followed by the Gaussian Pacesetter 2500 SPX-25 at 28,000 copies / hour.
In order to adapt to such a high speed, the structure of the spreader, stapler, and three-sided cutter of these devices has been greatly improved. Pacesetter 2500 SPX-25 spreader adopts three gripper structure, which improves the stability of spreader. Supra's binding machine has a pair of acceleration wheels installed on the front and rear separation shafts to meet the production speed of more than 30,000 books / hour; its stapler adopts a double-stapling structure, which is rotated and bound by 2 binding units, so For every two signatures in the past, the two binding units only work once, which not only improves the efficiency of stapling, but also reduces the vibration of the machine; the structure of the three-sided book cutter has also been greatly improved, and the front and side knives are both Independently driven, and adopts swing structure to improve cutting speed. In addition, in order to meet the demand for high-speed book stacking, Martini also introduced a high-speed counting and stacking device with a speed of 30,000 books / hour.
2. The degree of automation is getting higher and higher
The improvement of the degree of automation is mainly reflected in the three aspects of the automatic adjustment function of the format specification, the application of the shaftless transmission technology, and the perfect detection system.
(1) Automatic adjustment of the specification has become the development trend of the saddle stitching linkage line. As long as the length, width and thickness of the bound book are input through the screen, the controller can automatically adjust the format size of the binder, stapler, three-sided cutter and even stacker. Heidelberg ST450, Martini BravoPlus and Holler HSB10000 equipment all have this function. Moreover, BravoPlus also has the function of receiving network data, that is, it can adjust the machine according to the relevant data on the network, and realize the whole digital operation of pre-press, printing and post-press binding. The HSB10000 also has an automatic adjustment function for the binding head. As the characteristics of the signature change, the thickness of the binding will change accordingly. This fashion binding head will automatically adjust the components according to the actual situation of the signature to meet the production needs.
(2) Features of improved automation degree-shaftless transmission technology. The shaftless transmission saddle stitching linkage line removes the original mechanical transmission long shaft, and installs an independent servo drive device in each unit (including spreader, stapler, and three-sided cutter), coordination of each unit The operation is completed by the general control system. The application of shaftless transmission technology not only makes the movement process of each unit more stable, but also shortens the installation and commissioning time of the machine.
(3) Comprehensive monitoring of the binding process is the key to ensuring the quality of the binding. The general saddle stitching linkage line has the detection functions of missing posts, multiple posts, crooked posts, missed posts, blocked books, as well as the thickness of books and the number of nails. The high-end saddle stitching linkage line also has a cutting monitoring function, that is, it can detect the cutting quality of the three-sided book cutter; some pagers also have image recognition detection or barcode recognition detection functions to ensure the quality of the work of the pager . In addition, the sequential start / stop (Cascade) function is becoming more and more mature. Many machines already have this function, which can effectively ensure the binding consistency of the first book and the last book.
3. Continuous improvement of functions
Whether the accessory function is perfect is also an important reference factor for printing manufacturers to choose the saddle stitching linkage line. At present, the accessory functions of the saddle stitching linkage line mainly include the following aspects:
(1) Double and triple cutting and punching functions. For small-open booklets, such as CD-ROM booklets, the use of double and triple cutting can greatly improve efficiency, and a cycle process can produce 3 booklets.
(2) Automatic posting function. Both Heidelberg and Martini have automatic posting devices for customers to purchase, in order to reduce the labor intensity of workers and improve production efficiency.
(3) Paper jam pasting function. Now, many foreign customers have begun to pay attention to this function, that is, when the signature is run on the book chain, the paste is completed online, and it is synchronized with the running speed of the host. Use this function to easily paste CDs, product samples, feedback cards, etc. into the book.
(4) Code printing function. Through the coding device, the inside and outside of the book can be code printed, such as zip code, address, etc. Prima of Martini has this personalized processing function. In addition, Osako has plans to apply it to the next generation of saddle stitching linkage equipment.
(5) Bagging function. That is, after the booklet is processed, it can be automatically sealed with plastic bags.
(6) Add tray function. The packaged books can be transported to a tray on the back, and then transported out after a certain amount is packed. [next]
4. To digital development
With the development of sheet-fed and roll-fed digital printing presses, the post-press processing system for digital printing also followed in time. Although most of the on-demand printing technology is applied to short-form jobs (less than 1000 prints), this is not static. The functions of printing presses are becoming more and more powerful, especially the widespread use of web-based inkjet printers, and many digital printing houses have also begun to accept long-form work. This change in workflow prompted people to turn their attention to post-press processing solutions.
Digital post-press processing is very different from commercial printing in systems and workflows. They usually use "one-off" production methods. That is to say, the content and the number of pages of each book may be different, and the effect seen by each reader is also different.
(1) The Digi-Finisher binding and processing system jointly developed by German Holler and MBO has a variety of functions, which can complete the pagination, binding and cutting of printed products until the final finished product is output, and can also be equipped with books and periodicals Machine, automatic baler and other additional equipment. This Digi-Finisher processing system, which can input fixed data or adapt to variable data, can set data without stopping the machine, and can flexibly realize online or offline processing with the printing machine.
Digi-Finisher is a combination of Holler ’s saddle stitching linkage line HSB7000 and MBO ’s B-21 folding machine, which folds digital printed pages into four- or eight-page signatures, and then places these signatures on Holler Stapler on the saddle. The device has many vertical book buckets, so that digital printing materials can be combined with digital prints. Barcode scanners ensure the integrity of pages and signatures. In addition, the two units can also work independently. The B-21 folding machine can be used as a folding machine for folding processing; while the HSB7000 stand-alone machine is offline, it is a complete saddle stitching linkage line.
(2) Martini has always occupied an important position in the post-press processing field, and it is not outdone in the field of digital post-press binding. The Martini SigmaLine system is very comprehensive and can be used online with continuous web printers. If the online production method is adopted, a paper cutter can be installed at the end of the printer, and the processed pages can be transported out through it, and then the book block can be transported to the paper feeder of the binding machine through a special conveyor belt. At the bookbinding measuring station, each input book block is pressed with a certain pressure and is suitable for flexible jobs with variable number of pages. At the same time, the measuring station also determines the actual size of the book blocks and the order in which they enter the binding machine. The maximum processing speed of this equipment can reach 6000 volumes / hour.
(3) IBIS's high-speed Digi-Stitch DST2 saddle stitching equipment can work online with the web digital printing press. After the printed roll printing from the online printing system is cut by the sheet-cutting machine, enter the edge registration register feeding device of DST2 one by one, and the barcode reading machine checks the number of the printed sheet, and then each printed sheet Indented, folded and collated. The pre-printed cover is input through another paper feeder. After folding, it is automatically attached to the book block, and then bound by a saddle stitching device to form a booklet. Finally, the three-sided book cutter cuts it into a booklet that meets the format specifications. DST2 saddle stitching equipment can accurately adjust the thickness of the booklet without affecting the paper feeding, the adjustment range can reach 0.4 inches. The booklet of ultra-small specifications can also be processed with a center cutting knife. Digi-Stitch DST2-NL binding equipment has the same function as DST2 binding machine, but works offline.
(4) Duplo System 5000 maintains its leading position in the offset and digital printing markets. System 5000 can be used with any offset or digital printing equipment. Duplo also introduced IMBF software for the System 5000 product line, which can control 40 sorting units through the PC interface, and also allows the operator to select the sorting unit and the paper feeding sequence. In this way, people can bind color and black and white pages together in a reasonable order. In addition, this software can also be driven by a database, so you can create brochures with personalized data. If the appropriate folding / insertion unit is added, the system can also realize the postal function. [next]
Application is quick
With the rapid development of the global economy, higher and faster demands are placed on printed materials. To meet the high-quality and efficient market demands of printing companies, coupled with the rapid increase in labor costs in recent years, post-press processing automation and mechanization are inevitable Row. This undoubtedly brings new opportunities to post-press equipment manufacturers, and the market positioning and technical characteristics of various saddle stitching linkage lines are also more clear.
1. High-speed, large-scale saddle stitching linkage line
In the field of saddle stitching linkage production line, Martini has always been at the forefront of the industry, and the equipment has been recognized by our customers, but its high price is also well known in the industry. With the rapid development of other brands, it has seriously affected its development in the low-end market. Therefore, Martini will focus on research and development and promotion of the high-end market.
The two Supra and Tempo22 horse-riding linkages launched by Martini in recent years are aimed at the high-end market. Supra has a maximum speed of 30,000 copies / hour, a maximum of 30 collating stations, and a maximum cutting thickness of 13mm, which can be cut at full speed. The maximum speed of Tempo22 is 22,000 volumes / hour, and the maximum configuration of paging stations can reach 40. Both of these devices can meet the processing requirements of large quantities and multi-posts, and belong to the giant in the field of binding. Moreover, these two devices are equipped with JDF interface, with online processing capabilities.
Gauss successfully launched the Pacesetter 1100, a high-speed saddle stitching linkage line used in conjunction with rotary presses. The maximum speed of the device is 20,000 volumes / hour. On the basis of Pacesetter 1100, Gauss also cooperated with Banta Publications to develop Pacesetter 2500 SPX-25. At present, the production speed of this equipment is close to 28,000 copies / hour.
2. Medium-sized saddle stitching linkage line
Most printing plants need moderately priced medium-sized saddle stitching equipment, so this area is also the most competitive area for post-press equipment suppliers on the international market.
(1) Martini's mature products Prima and Bravo-T occupy a certain market share in this field. The maximum speed of Prima can reach 14,000 books / hour, and the maximum number of collating stations can be up to 16. The maximum speed of Bravo-T is 11,000 books / hour, and the number of collating stations can reach up to 14.
(2) The Heidelberg ST450 saddle stitcher is a perfectly designed binding device. It provides great flexibility without affecting the quality of the binding, and can maintain a production speed of about 14,000 copies / hour. The maximum number of stations is 24. ST450 does not use a fixed signature conveying device (or book bucket), each book bucket is an independent paper feeding system, and can be placed on either side as needed. The signature separation straws have independent vacuuming devices. If one fails, the delivery and opening of other signatures will not be affected.
(3) Following the launch of the HSB7000 saddle stitching linkage line and great success in the market, Holler Company also launched the HSB10000 saddle stitching linkage line. This device has a maximum speed of 10,000 copies / hour and can be equipped with up to 12 collation stations. Although its speed and maximum configuration of the whole machine are slightly inferior to other equipment, the high automation of this equipment has earned it a certain market share in the medium-sized machine market, and it is very popular in European and American countries with more expensive labor. The automation function of HSB10000 can be said to be armed to the adjustment of various components from the paging station, binding unit, binding head, cutting unit and other components that can vary according to the product processing width and thickness, until the lubrication and maintenance of the machine can be achieved Completely automated.
(4) The Tener series saddle stitching linkage line of Otani Company has also won a good reputation in the mid-size machine market. The Tener series saddle stitching linkage line integrates many useful products, and an independent signature scanner can make each signature fall into the correct binding chain. Moreover, Tener also has a monitor to identify whether the binding is normal, including a central lubrication system, a wireless remote control system that can turn the machine on and off, a digital caliper (relative to the mechanical design), and an error control system . Tener's ORF-836 rotating book bucket can be easily rotated to the proper angle, so that the signature can better enter the binding production line under high-speed operation. Each paper feeder has its own vacuum device, which can adjust the air pressure to an appropriate level. Another feature of ORF-836 is that it has high and low page numbers.
3. Small saddle stitching linkage line
Worldwide, the demand for small saddle stitching linkage lines has occupied a large share. Most of the products in this market were introduced by equipment manufacturers at the beginning of their production.
(1) Two of Martini's early products Valore and Presto belong to this category. Presto is also the most widely used in the world at present, and it is also the basic model of a series of Martini horse riding binding linkage equipment. It has a maximum speed of 9000 volumes / hour and can be equipped with up to 6 collation stations.
(2) After the introduction of HSB5000 by Holler, HSB7000 was also launched. The maximum speed of the HSB7000 is 7000 volumes / hour, and it can be equipped with up to 6 collating stations. The biggest feature of this linkage line is the use of a vertical paging station, which increases the storage capacity of the paging station, effectively reduces the pressure of the post to be transported on the transported post, and avoids the scratch of the post. Another feature is that the binding head does not follow the movement of the book, but only performs the upper and lower binding movements. At the moment of book binding, the book is stationary. This structure ensures the accuracy of book binding. Moreover, the adjustment of the device is simple. When changing from one bound product to another product, the adjustment can be completed within a few minutes without resorting to any tools.
(3) The Heidelberg ST100 prototype is a product of Brehme Stahland AM Imaging Corporation acquired by Heidelberg. The maximum speed of the linkage line is 9000 volumes / hour, and it can only be equipped with up to 4 paging stations, which belongs to the small saddle stitch linkage line.
With the rapid growth of labor costs in China, domestic printing companies' demand for saddle stitching linkage lines will become stronger and stronger. Printing companies should choose the appropriate equipment according to the characteristics, delivery time and economic strength of their processed products when purchasing a horse-riding linkage line, and do not blindly pursue brands or low prices. In addition, at present, through domestic technology introduction and independent research and development, domestic horseback-ordering linkage manufacturers have gradually narrowed the gap with imported equipment. Therefore, the diversified product types of saddle stitching linkage lines at home and abroad provide more choices for domestic printing companies.
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