Get Into The Fold

In an era of earlier job deadlines, shorter runs, increased quality and more complex jobs, efficient post-press operations are critical for a successful in-plant.

By Mike Llewellyn and Caroline Miller

SOLID FOLDING capabilities are critical to the success of an in-plant. That's what Mel Zischler believes.

As manager of Principal Financial Group Printing Services, Zischler oversaw the recent installation of a Challenge Machinery folder into his 33-employee in-plant in Des Moines, Iowa, where it will work side-by-side with a five-year-old Stahl folder.

"We had an application come through where we needed greater [paper-handling] capacity," explains Zischler.

While looking at folders, Zischler says he kept his eye out for a unit with easy job setup and rugged construction so the machine would be in the shop for the long haul.

Zischler's experiences with folders have taught him a few things.

"I'd recommend getting a vacuum feeder," he says, "because with a friction feeder you're always fighting with the wheels."

Zischler contends friction feeders have a greater tendency to pick up extra sheets, slowing down the finishing process as the in-plant's bindery operators work to correct the problem.

Folding machines are among the most popular pieces of in-plant equipment; they are installed in 97 percent of all shops, according to IPG research.

Some of those folders, though, have seen better days. Manufacturers say that investing in newer folding machines will bring updated technology into an in-plant to ensure much quicker job turnarounds, reduced paper waste, easier setup and more precise, higher-quality, folded products.

The Benefits Of Automation

Today's floor-model folder customers are investing in new folders primarily to reap the benefits of increased automation, says Don Dubuque, Standard Horizon product manager at Standard Finishing Systems.

"As run lengths decline, setup time becomes a larger percentage of total job time, which drives up the labor cost on jobs," he says. "Automation shortens job setup times, which translates into higher profits." He adds that automation also simplifies operation, so more operators can be cross-trained.

Less Expertise Needed

Today's new class of automated folders virtually eliminates the need for dedicated and highly skilled "folder specialists" to set up and run the equipment. For example, sheet format and fold patterns can be input on an LCD touchscreen, as opposed to being manually set, then instantly recalled from memory when the job reoccurs.

Finding qualified folder operators to run manual folders can be difficult, contends Stacey Porto, GBR Systems marketing manager.

"With an automated folder, a typical learning curve can be as little as a single two-day training session," she says. "The settings on some folder manufacturers' products are now done via an operator panel that will guide the operator through the setup process."

This automation often replaces most, if not all, of the need for makeready and operating skills.

"With complex folds, fine adjustments often have to be made, so the benefit of an automated folder where fine adjustments are made one increment at a time at the touch of a button is crucial in a bindery's productivity," she claims.

Quick Setup

The ultimate goal is zero makeready time. Hence today's computer-controlled folder now incorporates automated fold plates, fold roller gaps, alignment rails and delivery rollers. It also has programmable job functions where an operator can store a fold in memory and recall it at the touch of a button. This feature cuts makeready and fold changeover times significantly, in particular for difficult folds such as gatefolds.

"Fast makeready and quick turnaround times result in high productivity, whilst retaining the highest folding quality available," claims Hartmut Sohn vice president of MBO America.

Job Memory Crucial

Job memory is a particularly important feature to consider if a user runs a number of different jobs.

"This can take labor savings to an even higher level, allowing for instant recall of recurring jobs," states Dubuque.

Versatility is also essential for printers when purchasing a new folding machine, according to Wayne Pagel, president of Kepes Inc. Many processes that were traditionally a separate letterpress operation are now being incorporated into the folding/finishing process. These include high-quality scoring of heavy stocks, pattern perforating, and some cutting and punching operations.

"Printers are being asked to finish a wider range of stocks, in more complex processes," Pagel says. "This calls for modular folding systems that can be reconfigured on a job-to-job basis. The sequence of machinery needed to 'fold' the job may involve 10 or more pieces of folding and finishing equipment. From the feeder on through to the delivery, every piece of the process needs to be able to interchange with another." As a result, he says few printers can justify a dedicated system only capable of one type of process.

Value-added Functions

GBR Systems' Porto agrees: "Our clients are also looking for a folder with value-added functions, including gluing, nesting prior to folding, pressure sealing, gate folding, soft scoring for toner-based color, and a folder that can operate in-line with cutters, roll unwinds and digital printers."

While technology offers new possibilities, there are some age-old standards to remember when purchasing a new folder.

Quality of construction is still key, especially if you have multiple-shift usage, reports Dubuque.

"Check out the drive system, the bearings, the fold plates and rollers. Most of this equipment is purchased on a long-term lease, so customers want to make sure they are going to have an asset that can still perform after 48 or 60 months," he notes.

Last, the quality of the fold is essential, as customer expectations have only risen. As run lengths decrease, fold quality from first sheet to last becomes critical, since there is little or no tolerance for makeready waste or spoilage.

Unfolding What's Available

Floor-model folder vendors offer a wide range of features to fit every need. Here is a look at some of the machines currently available in the marketplace.

The Mathias Bäuerle Multimaster CAS 52-B SetMATIC computer-controlled folder from GBR Systems (www.gbr.com) is heralded as the first folder with fully automated settings. Fold plates, patented fold roller gaps, alignment rails and delivery rollers automatically move into their correct positions according to the data entered by the operator on a central control panel. No manual adjustments are necessary, resulting in very short makeready time, no need for technical setup people, less waste and precise folds.

The new Standard Finishing Systems (www.standardfinishing.com) Horizon AFC-544AKT folder features automated setup through a user-friendly touchscreen. Up to 100 different job settings can be stored in memory, and automated makeready is accomplished in as few as 13 seconds. The feeding section combines a rotary vacuum feeder with a suction head for efficient feeding of a wide range of stock, for sheet sizes up to 21.2x29.5˝.

The DF-520N automatic-setting folder, from Duplo USA (www.duplousa.com), has six pre-programmed folds and unlimited custom folds. Offering touch-button operation, this folder requires no adjustment for paper thickness and accepts paper in a range of sizes. The DF-520N has speeds from 45-170 sheets per minute. No manual adjustments are necessary since the machine recognizes paper size. The jam detector automatically stops the folding process when there is a blockage. The control panel displays programming and error messages.

The MBO America (www.mboamerica.com) B21 folding machine is available with the standard MS control with automated suction range and sheet gap. Also offered as an option is the MC (micro-processor) control that monitors and controls misfeeds, jams and sheet length. The top-of-the-line Rapidset version is computerized with automatic fold plate adjustments that can be linked to the MBO Datamanager and is CIP-3/4 compliant.

The Baum (www.baumfolder.com) 15GSL floor-model pile folder is offered with GSL automatic fold roller tensioning, HDN gear-drive system, toner-release precision urethane rolls, pile air feeder, diagnostic messages, as well as built-in total and batch counting. It handles up to 15x23˝ sheet sizes.

The TD 52, from Heidelberg USA (www.heidelbergusa.com), is designed to handle even the shortest runs. The folder can compress turnaround time between jobs dramatically by automatically positioning side guides and buckle plate positions. A readout on the operating panel also provides positions for slitting, scoring and perforating blade, plus fold roller settings.

The Medalist 870, from The Challenge Machinery Co. (www.challengemachinery.com), folds up to 30,000 sph of 8-1⁄2x11˝ stock, and handles up to 14x20˝ stock. It features air separation, vacuum feed, adjustable metallic sheet separator, flip-up swing deflector, combination rubber/steel rollers, adjustable roller calipers, top-mounted control panel with built-in sheet counter, delivery area jam detector system and noise hood.

From MBM (www.mbmcorp.com) comes the 352S air suction folder. It handles high volumes and a range of stocks, including freshly printed and coated paper. It is a bottom-fed, top-loading folder that handles 30,000 sph for paper sizes up to 12-19⁄32x17-23⁄32˝.

The Vijuk (www.vijukequip.com) H&H KL 112 miniature/pharmaceutical folder offers a quick-set roller adjustment and transfer unit for trouble-free transport. Each station is available with two, four, six, eight, 10 or 12 folding plates for right-angle or tandem configurations. It can be equipped with a vertical stacker or shingled delivery system and continuous suction or pile feeders.

Mel Zischler, manager of Principal Financial Group Printing Services, recently oversaw the installation of a folder from Challenge Machinery.