The State of Perfect Binding

 Shorter runs, as well as runs of one, along with the emergence of digital printing have considerably changed the printing market – and with that, the capabilities demanded from perfect binding technology.

“Some of today’s entry-level perfect binders are designed for longer runs, as well as one-up production, making them a good choice. In the mid-range space, digital manufacturing and binding is also possible, particularly because of developments in touchless workflow and digital binding,” says Jim Kaeli, Muller Martini solutions manager, book technology and hardcover.

Because of its flexibility, perfect binding is utilized for a variety of hard- and soft-cover products – from books and catalogs to magazines, photo books, and more – in all types of industries. It can accommodate multiple types of input, including digital cut sheets, signatures, or sewing book blocks. In addition, perfect binding works with both hot melt and PUR adhesives and delivers exceptional binding results.

Seeking scalability

A key factor when purchasing an entry-level perfect binder is its scalability. In other words, for a modest, incremental cost, can you add additional features and functions to the machine as your business grows or moves into new markets.

When buying a perfect binder, ensure that both your current and future are met. According to David Spiel, Spiel & Associates, there are two major considerations to take into account: the strength of the book the perfect binder can create, and how automatic it is.

Make sure the machine can “make a good book,’” says Spiel. “Do the pages hold together?” A critical element with perfect binding is what happens to the book before it is glued. “The perfect binder needs to prepare the spine properly,” he explains. 

You’ll want a perfect binder with automation features, of course, but just how much depends on volume and throughput. “Everyone wants machines that do everything by itself, but maybe you don’t need all that automation,” notes Spiel.

“Our Sterling DigiBinder sets up automatically from 2 sheets to 2-1/4 inches without any changeovers,” explains Spiel. “It also roughs the book; instead of just notching. That’s what I meant by preparing the book prior to gluing. With notching, you are using just one or two pins. A rough, on the other hand, uses a serrated blade to rough the entire edge of the spine, which allows the glue to seep in better.”

It’s the roughing characteristic that allows the Sterling DigiBinder to handle coated stock very well.

“The DigiBinder is a self-adjusting perfect binder. The pneumatic clamp and nipper adjust automatically. A compressor is included. Bind a thin book, then a thick book, without any adjustments whatsoever. The unique, heavy-duty roughing blade allows for the binding of offset stock, coated stock, and stock with oil based or wax based inks,” says Spiel.

On the subject of PUR, Spiel says that although his company will soon have a new PUR binder coming out, “Ninety percent of the work out there doesn’t require PUR. Its only advantage is that it can bind really thick stock. Many customers think a book will fall apart if the book isn’t PUR, but that’s not the case. There is a use for it; it’s just not as important as people think. The PUR binders are also much more expensive.”

Muller Martini offers a suite of perfect binding solutions, from entry-level machines like its new compact Vareo, to the higher-end capabilities provided by the popular Alegro perfect binding line which handles both short- and medium-runs in either digital or offset production. “All of our solutions offer considerable automation in terms of feeding, measuring, and hands-off operation,” says Kaeli.

The Alegro can process up to 7,000 books per hour, says Kaeli, and is extremely versatile because it offers a lot of upward mobility in terms of automation and touchless workflow features – particularly with regard to a barcode cover and back matching system, as well as its ability to quickly process variable thicknesses in ultra-short runs.

In addition, the Alegro delivers scalability, allowing users to add to and expand or augment its configuration and capabilities in order to satisfy growing business demands. Each Alegro component is servo-driven, meaning they can be individually controlled without the need for line shafts or chain drives. “That translates into a more reliable and consistent performance throughout the life of the machine,” reportes Kaeli.

In terms of its ability to handle multiple print inputs, the Alegro binding line can be quickly changed over among softcover, hardcover, and digital production, with fine adjustments being made “on the fly” without operator intervention. “Further efficiencies are achieved through Muller Martini’s Motion Control Technology, which reduces the processing time for each job, lowering costs and generating additional production capacity,” Kaeli notes.

The Standard Horizon BQ-470 fully automated four-clamp perfect binder also offers fully automated setup, producing up to 1,350 perfect bound books per hour, with four clamps that travel on a vertical elliptical track.

The BQ-470 is the latest in an expanding line of products that draw on Horizon’s core competence in finishing automation. The BQ-470 binder’s 10.4” LCD touch-screen is used to provide stepper motor-controlled automation to the professional-quality mid-range binding market. The BQ-470 can bind books up to 2.5” thick, and interchangeable glue tanks support both EVA and PUR adhesives to meet varying customer requirements. This perfect binder fits a sweet spot in short-run professional-quality book production with full automation and touch-screen control. And the ability to swap-in a PUR glue tank lets the BQ-470 serve an even wider range of applications, including digital color books.

Duplo’s new DB-290 perfect binder, which produces up to 200 books per hour, was on display at Graph Expo 16. Enhancements include new milling and notching blades, along with a new side glue tank for improved glue application. The side glue is designed to provide better adhesion and help form the book spine. In addition, new formulated glue performs better on digital coated sheets.

Developed as a good fit for short-run, on-demand applications, this automatic perfect binder provides centrally located controls for single-operator efficiency. A double pass over the roughening cutter is designed to deliver superior notching for superb glue penetration, and its clamping and nipping system is designed ensure consistent square binds.

Working with digital print manufacturers

Given the increased complexity of finishing variable products, Muller Martini continues to spearhead innovation “with the smart connectivity of our finishing systems, which enable optimum variability and flexibility with regard to runs, format and content,” says Kaeili. “And, we will work closely with digital print manufacturers, whether web or cut-sheet, in order to engineer efficient solutions and workflows that seamlessly accommodate all processes.”

“Muller Martini’s launch of the Finishing 4.0 platform,” says Kaeli, “was a huge success at drupa, and the capabilities and features of our perfect binders and other bindery equipment powerfully reflected the principles of Finishing 4.0,” including:

• Automation within every phase of the printing process, from pre-press to distribution.
• Touchless workflow, which employs connectivity and automation in order to initiate production changes without manual intervention, and is typically achieved through simple barcodes or more sophisticated JDF integration.
• Variability in run size, product size, and content, including personalization which is becoming extremely popular, particularly within the commercial space.

“At drupa, our demonstrations generated significant attention because they were fully integrated,” Kaeli says. “We produced a wide variety of traditional, digital and hybrid products at the front end of the booth, then finished them, through perfect binding, saddle stitching, sewing, etc., throughout the booth. All told, well over 30 different products within nine work centers were completed. Not only did booth visitors get to experience these processes up-close, but they saw the tremendous opportunities that exist in terms of product variability.”