Into the Fold

New-age folding machines are becoming the glue—literally—that holds together print and bind jobs and helps make them more profitable. Not that there aren't interesting developments in more conventional folding technology. Consider Baum, for example, whose expansive folder line now includes wider-format, continuous-feed units (26″ and 30″) for increased productivity.

But "learning" and gluing in line are two folder features gaining in popularity and helping printers and binderies save time and costs in computer-integrated manufacturing (CIM) environments. Some manufacturers are perfecting the adhesion process, which previously was fraught with bottleneck set-ups and clean-ups, not to mention extensive hand-holding by highly skilled operators. Binderies and finishing departments today are not eager to job-out gluing, choosing instead to grow a new profit center internally and offer faster delivery.

Folder manufacturer MBO America now carries the Vario-Glue applicator from hhs Gluing Systems. Based on a non-contact electromagnetic gun, somewhat similar to inkjet printing, the technology was originally developed in Germany more than a decade ago. This "hot-dot" gluing has been continuously refined. The system features a pneumatic shutter that automatically seals the nozzle when the gun is not operating, preventing adhesive from drying in the tip. Popular in both packaging and brochure manufacturing, the Vario-Glue device can produce 8-, 12- and 16-page signatures, as well as edge and auxiliary gluings.

Brandtjen & Kluge offers two folders with in-line gluing capabilities: the Kluge UniFold and OmniFold automatic folder/gluer. By simply removing the folding section, the UniFold system is transformed into an in-line folding and gluing solution capable, in some versions, of handling sheets up to 29×32″.

"The critical thing to us was versatility," says David Hutchison, CEO of BrightMarks, a printer/finisher outside Kansas City, KS. His firm uses the device on everything from presentation folders to CD sleeves. "The UniFold allows us to run them all," he says. A modular design gives flexibility to add features as client demands grow. The system incorporates a patented vertical buckle fold unit, which, combined with the final fold unit, offers added versatility.

For creative and compact folding, Vujik Equipment's Miniature Glued Booklet System folds and glues booklet spines (up to 40 pages) at one station of the H+H KL 112 folder. Popular among the pharmaceutical, cosmetic and small-packaging industries, Vujik says its mini system (sheet range 2×2¾″ up to 17 5/8×47″) also works ideally for direct-mail inserts, CD packaging inserts, invitations, announcements and other small, folded print products. Indeed, producing petite folds for pharmaceutical package inserts has led to additional business for Arlington Press of Brooklyn, NY. "Customers put me in touch with their advertising agencies," says Robin Henfling, president, "and besides providing them with informational leaflets, outserts and other packaging-related components, we now produce direct-mail promotional pieces for them."

The Glue-Folder might be the ticket for printers specifically into direct mail. It features five fold styles for plain paper (up to 8½×20″ forms), four for specialty stock, one for postcards. As an add-on, it can transform almost any folder into a gluer.

In addition to being flexible and versatile, the new class of folders is artificially intelligent, too. Demonstrate what kind of folds you want—roll, accordion, map, gate, double-gate—and these high-tech systems "learn" how to execute them. And they are also quick studies. Heidelberg's Easyfold folding machine, for example, retains preprogrammed settings for the six most commonly used small-format fold types (both parallel and right-angle)—and has memory capacity to store three more, despite its compact application (it's designed for short runs on sheets up to 14×20″). For more commercial applications, the Stahlfolder TH (buckle-plate) and KH (combo folder) models feature Heidelberg DCT automation that integrates smoothly into the workflow, yielding quicker change-overs and higher output.

On a grander scale, MBO's B26-S/644 Perfection folder has enough microprocessing power to recall 62 standard impositions and 250 optional programs, yielding a virtually unlimited number of folds. Like the B26-S/444 and S/664, the "brainy" S/644 features touchscreen technology and a digital Navigator control that automates the folding process and reduces production errors.

In a similar configuration, GBR Systems' Mathias Baüerle (MB) CAS folders feature computer-controlled technology with seven preprogrammed folds and push-button access to another 60 custom-fold types. GBR's CAS 52-B SetMatic (maximum sheet is 20 7/16×33 7/16″) automatically sets fold plates, fold roller gaps, alignment rails and delivery rollers.

Some of these "smart" folders can be fed more than just paper. (See sidebar.) They accept CIP3/4 and JDF fold plan information, as well.