Finishing The Job?The Right Way

What are you looking for in a collator? Find out what manufacturers suggest.

WHEN YOU complete a printing job that meets your client's specifications, adding the finishing touches are like putting the icing on a cake. It adds oomph.

But when an otherwise beautifully perfect-bound book is botched up with sloppy and seemingly careless stapling and stitching, elegance goes out the door and disappointment comes flying in.

Nowhere was this more apparent than during the recent judging of In-Print® 98, the joint In-Plant Graphics/International Publishing Management Association printing contest. The judges, meticulous and discriminating in their approach, eliminated many otherwise beautifully printed projects because of bad folds or stitches—and they didn't take pleasure in eliminating them, either. In fact, it seemed to almost pain them that they had to throw their first choices in the reject bin because of a staple that was off or a fold that was uneven.

You, as in-plant employee, have to show your best side all the time. As Contest Judge Debbie Leone, of St. Joseph's University, explains, "When there's a mistake...the in-plant looks bad, not the actual client."

Leone stresses that it's important to present the job as professional as possible—because your customer is counting on it.

When shopping around for a collator, managers say you should look for one that will fulfill your needs, immediate and future.

Setup is a feature that should help narrow down your choices. Whether you choose automatic or manual depends on the work you're doing.

If your shop does long-run work, then automatic setup isn't crucial. But for shorter run lengths, automatic setup is a plus. Spending just a few minutes verses a half-hour decreases waste time and increases productivity.

"If your job will take 30 minutes, you can't afford to spend 10 minutes setting up," asserts Mark Hunt, marketing manager for Standard Finishing Systems. "That's one-third of production time. In-plants can't afford wasted time like that, especially for short-run work."

Less Experience Required

Though they are more expensive, automatic setup collators require less expertise to operate. All you need is a good working finger to be able to push the button and, voila, the machine is ready for action. But you have to be certain that this application fits your market and is necessary for your operation.

In other words, will the machine pay for itself?

Don Schroeder, vice president of sales at C.P. Bourg, explains it this way: "If you're doing six changeovers during one eight-hour shift, then automated equipment will offset the expense," he says. "But if your run lengths are longer, and you're not doing as many changeovers, then manual would probably be your safest bet."

Just make sure the machine is user-friendly, Schroeder stresses.

Finding The Right Fit

To choose the collator most suited to your operation, you must first look at what you're doing after the collating process, says Saul Spiel, president of Spiel Associates.

"There are two basic ways of collating," he explains. "One is for single sheets, which are generally for short-run work and bookletmaking. This is much slower than other collators.

"A gatherer collator for perfect and mechanical binding runs at a much faster level," he continues. "This machine can collate 5,000 an hour as opposed to 2,000."

When you're ready to buy, adds Hunt, of Standard, you need to look for three key utilities: speed, reliability and programming.

"In-plants need to look for ease of operation with simple computer operator interfaces, advanced programming that produces a high level of productivity, and reliability in speed and uptime."

He says that while speed is important it becomes irrelevant if the equipment is experiencing a lot of downtime.

"Even if the system can run 4,000 books at a time," he comments, "if it's down all the time then you'll only get 2,000 books done. That will influence your total productivity."

Computerization: A Waste Of Money?

Though Hunt advocates computerized controls, Spiel feels differently. A computer-controlled collator, he contends, not only doesn't increase the speed, but it drives the cost to almost double. He feels that it's not cost-effective, especially since in-plants are only allotted a set amount of money each year for new equipment.

"I feel that in-plants are getting duped into buying these high-tech machines with a lot of pretty lights on them," says Spiel, whose company also builds finishing equipment. "Machines should be simple and strong, so I know when I turn it on in the morning it will work all day."

When purchasing any piece of equipment, managers have to look at risk and reward, advises Spiel. Ask yourself how much it will cost and how much it will produce in an hour. Realize that this is an investment that should last for 10 to 15 years.

"It's a simple math equation," he maintains. "[Ask yourself], 'is this going to make me money?' "

Pete Short, vice president of sales and marketing for System Finishing Equipment, takes that concept a step further and says the collator should evolve with the customer.

"You have to ask yourself, 'what does this machine bring to the end user?' " he advises. "Look at your applications and determine which direction you want to go in."

He also suggests that if you can't afford to buy the machine you really want, put your money in the bank until you can.

Don't get an inferior device, he says; if you have to wait, then wait. At least then you'll get a collator that fits your needs.

Suction Feed:

Is It Really Better?

What's the difference between friction and suction-feed collators? Just two vital factors: price and professional look.

A sheet that is friction-fed is rotated by a rubber tire, and the pressure between the sheet being fed and the sheet it is being separated from can generally cause marking and smudging.

Suction- or vacuum-feed collators use either pulsed air, a stream of air or a combination of the two to separate the sheets prior to feeding. By using air to separate the sheets and a vacuum to pick them up, marking is eliminated.

Another plus of suction-feed is that you can use coated paper. With friction-feed collators, you cannot.

According to Standard Finishing even though friction-feed systems have been traditionally effective for basic one- and two-color applications, and the cost per bin has been less expensive, suction-feed collators dominate because of increases in short-run jobs, digital printing and high-quality work.

"Customers are looking for on-demand solutions, faster turnaround and higher quality," says Bob Flinn, Standard's director of business development. "As a result, many in-plants are reassessing their finishing option in general...and turning to suction-feed collating in particular."

He says that even with the top friction-fed systems, "it's not a question of 'will the marking occur?' as much as 'when?' and 'where?' and 'how much?' "

Suction-feed systems also run as high as 5,000 cycles per hour, reportedly have less down time, and offer increased bin capacity and the ability to load while running.

But despite the problems with using a friction-feed machine, it's still an old reliable for saddle-stitched books. And it's more affordable than suction.

Still, Flinn says that's not enough; factor in the cost of producing sub-par work and losing customers, he says.

"In this light, the question isn't, 'can I afford a suction-feed collator?,' " he says. "It is, 'can I afford not to have one?' "

What To Look For

O.K. You've got the green light from management to update your shop and purchase a collator. Now here comes the hard part: which one do you choose? Here are some tips from vendors to help you get the best deal for your money.

• Never purchase on price alone. Look at your applications, run lengths and the material you use.

• Look for user-friendly interfaces.

• Determine the cost of operating, including parts and supplies.

• Survey the market, ensuring that you are dealing with a reputable manufacturer.

• Make sure the dealer offers a demonstration site so you can test the equipment for time and accuracy.

• Bring in a sample of the work you'll be doing and perform the job on-site to see how your jobs will be done.

• Perform changeovers. Allow the dealer to show you how the collator can change quickly from one format to another.

• Determine your needs. Before buying, decide if you want a workhorse for strength and speed or a space-saver with quick set-up that can do short- and long-run work.