Large Formats Gain in Folding

Large-format folders, which measure 36" or wider, occupy a minor-sized segment of the postpress finishing market but one that is growing in importance.

The folders, which are popular in Europe, are being sought after by printers in the United States for their production versatility, array of add-on options, and ability to accommodate both small and large jobs with quick set-up times and fast production speeds.

"Normally we sell only three to five large-format folding machines per year," reports Hans Max, MBO America's president. "But this year we're on track to sell 10 or more. It may be because these larger printers have been using older equipment and realize it's time for an upgrade.

"Or perhaps the reason is simply increased productivity," he continues, "since we say our larger-format Perfection folders outpace other machines by a factor of three or more."

Heidelberg's Stahl division offers the 36" TD-94 and and 44" TD-112 machines. At the Print 01 show, Heidelberg introduced its new ACC 2.4 digital controller for the Stahl folders, including the TD-94 and TD-112.

The new controller controls the peripheral devices used for gatefolding, gluing, and timed perforations. The ACC 2.4 can simultaneously control two gatefold buckle plates or two spot-gluing guns. Other options include two EAP single section perforation heads, one gatefold buckle plate and one spot-gluing gun, or one gatefold buckle plate and one EAP head.

The ACC 2.4 controller allows gatefolding production at 15,000 cycles per hour while precisely controlling the switching times for the new FFP gatefold buckle plate from Heidelberg. In addition, the ACC 2.4 supports interrupted glue lines, variable spot gaps, and different spot sizes. Further, auxiliary gluing is possible, to give the best possible finishing effects for envelopes with flaps on gatherer-stitchers and adhesive binders.

Timed perforations are often used in cases where post cards are to be removed from a larger brochure by being torn along an angled perforation. The ACC 2.4 controls the EAP heads needed for this, making possible the production of these otherwise complex yet particularly attractive products.

Two EAP heads can be used at the same time, and controlled independently of each other. Each EAP head can carry out up to four timed perforations per sheet.

MBO America offers two new large-format models in its Perfection line, the 40x59" B-40 and a 44x59" B-44, which have the same automation features as the smaller Perfection models, including sheet control, gained via a series of patented engineering designs such as the vacuum infeed and vacuum alignment system. These designs, says MBO, result in a folder that runs consistently at a high speed.

The company notes that the Perfection is the only marbleless folder in the world, a design that, it contends, eliminates damage to sensitive papers.

Recently, MBO added the Navigator digital microprocessor-controller system to its folders, to gain machine control, production monitoring, and machine adjustments. The unit controls such functions as optimal speed adjustments in folding units and deliveries, and settings of speed and length of single stream and delivery.

The 15" Navigator touch-screen display includes job management data and automatic settings of counter and infeed, machine speed, and folding impositions along with auto-fold settings. MBO says the controller integrates into today's digital workflow and machine-networking culture, and elevates operator guidance and auxiliary settings.

"On larger-scale MBO folding equipment, computers assist the operator in shortening makeready times, troubleshooting or diagnosing a rare problem, and monitoring production numbers," says MBO's Max.

He adds, "As a result, most customers claim a productivity increase of 20% or more."

Area Trade Bindery, a 275-employee trade shop that has been located in Burbank, Calif. for 34 years, is to receive a new MBO Perfection B-44 folder early this month. The three-shift operation, which prides itself on offering virtually any type of postpress operation including perfect binding, miniature binding, layflat, and PUR adhesive binding, has a wide assortment of equipment in its 80,000-square-foot facility.

Area Trade Bindery caters to printers nationwide.

"We're pioneers in our industry," says Ray Ahlich, president of Area Trade Bindery. "Printers know they can turn to us for any type of postpress needed. We already have work for the new folder; it's going to give us the versatility to produce large and small jobs. We'll be able to put a small two-up letterfold job on the machine as well as sheets up to 50" long."

Another use will be the folding of large sheets of posters and maps, which are sent to Area Trade Bindery for finishing. One job for the Triple-A Automobile Club involves finishing maps for the entire country. Maps that used to be hand-folded in Mexico will now be folded automatically on the company's new folder.

"We've seen a big difference in folders compared to just 10 years ago," says Ahlich, whose company already operates four large-format machines. "The newer machines have more automation, more folding plates, and better roller systems, and permit much faster set-up times."

Large-format folders have been instrumental in the success of Phoenix Color, a 120-employee book manufacturer located in Rockaway, N.J. The company specializes in the prepress, printing, and finishing of illustrated four-color books, such as craft, cookbook, and children's titles, in both hard- and soft-cover editions.

Phoenix Color, established in 1979, is now the largest producer of book jackets and components for major book publishing houses. In Hagerstown, Md., it operates three facilities: a web printing plant for trade and educational books, plus two book component plants.

Phoenix Color also operates a prepress and proofing location in New York City to enable publishers there to quickly review proofs.

The Rockaway, N.J. plant is a complete Heidelberg shop, including automated platesetters, three 40", 10-color Speedmaster 102 sheetfed perfectors, and two Stahl TD-94 and TD-112 folders.

"We've been operating the Stahl folders for two-and-a-half years and we love them," reports Mitch Weiss, chief operating officer of the thin book division, which is based in the Rockaway plant. "Combining them with our 40" sheetfeds, we can produce a 16-page signature from one sheet. We also use them to produce accordion folds for our oblong books, right-angle folds for our upright books, and even more creative folding techniques, such as gatefold books. At the same time," Weiss adds, "the machines feature dramatic set-up and running speeds."

In line with the folder, Phoenix Color has installed a thread seal that is stitched to the gutter and simulates a Smythe-sewn book. Says Weiss, "This technique costs a lot less but helps our customers keep their costs down. It gives us a great competitive advantage."