Paper Folders - Accessories Add Sparkle

Today's folding equipment must do more than simply fold paper. In-plants want additional features to help them keep pace.

by ERIK CAGLE

ACCESSORIES ARE to folding machines what cherries are to cheesecake—sweet.

Printers still want folders that are easy to operate, with short setup times, but auxiliary equipment for scoring, slitting, perforating, gluing and plow folding can greatly augment the humble folder.

The aforementioned features are among the most requested by customers, according to Wayne Pagel, president and owner of KEPES. He believes a vacuum table that allows product sampling, and plow folds with gluing to close the product are also sought after.

"These new folders need to be modular," Pagel states. "Today, the feeders can be separate from the folders, and each unit in a finishing line needs versatility. This is often required because one machine can no longer be dedicated to one type of product."

KEPES offers the M7 Special, which includes a choice of four fold roller diameter options for various weight products, as well as options for up to 16 fold plates and machine widths at 63˝ maximum for specialty products.

Zero-makeready buckle plates are a popular feature on folding machines, according to Brigitte Cutshall, postpress marketing representative at Heidelberg USA. The sheet stop can be adjusted via a knob control and be used as a swing deflector.

Delivery systems are often overlooked as well, Cutshall comments, as the full benefits of faster, automatic folding equipment cannot be realized if the system does not keep pace. Heidelberg has enjoyed success with its Vertical Stack Delivery.

"The function for this unit includes counting of single sheets and batching, marking by lateral shifting and double pressing of a single sheet," says Cutshall. "It can deliver as many as four-up."

With a lack of qualified operators in the market, Cutshall believes customers are seeking more automated and less labor-intensive equipment. In response, Heidelberg is offering the 20˝ Stahl TD52 and 30˝ TD78 folders. The 52 has standard features, such as a flat pile feeder, automatic buckle plates and DCT 2000 comfort control. The 78 has the same basic standard features, along with a continuous round feeder.

Other Popular Options

Pressing and/or stacking deliveries continue to be popular options, according to John Porter, division manager for LDR International. In-line gluing, he adds, is still highly desirable.

"The ability to finish small books on the folding machine can be very cost-effective," Porter states. "Manufacturing of return envelopes is only one of the many different products that can be done in-line on the folder with the modern glue systems."

The Shoei folding machines offered by LDR have made their mark in computer-assisted setup and are available in the standard configuration, with manual settings for the fold plates and caliper settings on the fold rolls.

Bundling And Banding

Customers are finding a desirable return on investment with auxiliary equipment such as presser/stacker deliveries, bundling and banding machines, as well as gluing systems, according to Hans Max, president of MBO America. His company is offering the BA-900 bander/bundler that can run in one-, two-, three- and four-up production mode.

Max also notes a current labor shortage, particularly in the postpress area, which has prompted customer calls for machines that are easy to operate, more electronic than mechanical and inexpensive to maintain.

With adjustments conveniently positioned, a single operator can run the MBO IFF20 and still do fast changeovers. Produced to handle continuous forms, the IFF20 has stainless steel buckle plates with micro adjustment for sheet stop. Its spiral fold rollers boast a very tough grip.

MBO also offers the Navigator system with an optional 15˝ color touchscreen monitor. By utilizing PLC technology, it allows the Perfection folder to be integrated into a digital workflow. The software gives operators instructions for troubleshooting.

A Good Balance

Finding the correct balance of automation and manual setup features is important to produce quality and timely production, contends Mark Pellman, marketing manager for Baumfolder. Too much automation, he cautions, can remove the adjustments needed to compensate for printing and cutting variations.

"Another factor in today's folding machines is the increased amount of recycled papers with ever-changing physical properties that require a folder to maintain a positive drive on the paper without slippage," Pellman says. "These paper changes affect the paper grain and creasing properties of the paper."

Pellman notes that all Baum floor model folders have been updated to meet these needs, with more operator-friendly features for the beginning operator to easily set sheet gaps and vacuum adjustments. The Baum 2015 is its latest offering, a "next step" for the business that only has small-format printing and the volume to move up from a tabletop folder.

In-line Folding And Wrapping

In-line folding with wrapping capability and the ability to add additional FSIs to the final package are a few of the features customers want, according to Josie Muigai, marketing manager for Buhrs Americas. She also feels press speed, page count and off-line applications are influencing the manner in which folders are being manufactured.

"The systems need to run at higher speeds, but still maintain a good fold," Muigai notes. "With higher page counts, it gets harder to fold at higher speeds. Many folders need to be easy to set up and run in different areas of the plant. Therefore, portability is something customers seek."

The Buhrs-ITM quarterfolder is a high-speed, knife-type folder used for quarter folding newspapers or press/trimmed signatures at speeds up to 23,000 folds per hour. The folder can be fed by a variety of feeders and can be easily incorporated into a number of collators or other finishing systems.

Stacey Porto, marketing supervisor for GBR Systems, believes printers are looking for folders that automate the bindery process so they can deliver product faster and more cost-effectively. Increased labor costs, the lack of qualified operators, and customer demands for flexibility and quick turnaround are driving printers to rely on automated folding technologies.

GBR Systems offers a computer-controlled Mathias Bäuerle (MB) CAS 52-B folder with the SetMATIC system. The folder offers automated features such as automatic setting of fold plates, fold roller gaps, alignment rails and delivery rollers—all set by computer calculation. When one of the 60 custom fold jobs is recalled, fold sizes, speed, sheet gap, shingling of sheets, suction length, counting functions, double sheet and paper travel control, and alignment rails automatically move into their correct positions based on the data previously saved.

Challenge Machinery offers a unit that falls somewhere between the tabletop and floor models. The Medalist 870 folds up to 30,000 sheets per hour (sph) and is available with a right-angle folding attachment. It features flip-up swing deflectors that allow setup changes without completely removing the plates, as well as a swing-away feed table for easy access to the lower fold plate. Other features include air separation, vacuum feed, adjustable metallic sheet separator, adjustable roller calipers and top-mounted control panel.

The Brandtjen & Kluge UniFold folding and gluing system provides both productivity and versatility with a modular system. The UniFold's unitized system provides versatility. The buckle fold unit, final fold unit, TransTable converting unit and stacker unit are all portable, allowing for multiple configurations and applications.

The MBM 352S Air Suction Folder is a versatile folding system for in-plants with high-volume folding needs. Folding up to 30,000 sph, the MBM 352S can handle a variety of paper, including coated stocks, which are unsuitable for friction-feed models. The 352S is equipped with two fold plates and a suction feeder, which provides continuous reloading and patented polyurethane-foam rollers that make fold roller pressure settings unnecessary.

Standard Finishing Systems recently introduced the Standard Horizon AFC-504AKT floor model folder. It includes a user-friendly color touch-screen control panel that displays fold formats and sheet sizes for easy selection. Up to 50 different job settings can be stored in memory, and automated setup can be accomplished in as little as 15 seconds with precise stepper motors to drive end stops and fold plates. The AFC-504AKT handles a range of papers up to a maximum sheet width of 19.2˝.

Count Machinery offers several folding units, including the midsize Count-Fold 235 S, an airfeed, modular system. Standard features include adjustable roll calipers, poly/steel combo rollers, scoring attachment and sealed bearings. The unit folds up to 30,000 sph.

The Profold GPS 4000 self-mailer system automates the production of the self-mailer-style mailing piece. It includes Profold's parallel and right-angle folder, tabbing unit, air base transport, ink-jet addressing system and stacking conveyor. The return on investment is less than a year, depending on volume of mail.

Tabletop Folders

New to Graphic Whizard's product line is the FoldMaster 250, a 17˝ air-feed folder capable of running up to 25,000 sheets per hour (sph). Perforating, scoring and slitting is done before the fold rollers using individually depth-adjustable accessory holders. You can fold sheets up to 15˝ wide or remove the upper fold plate and perf/score stock up to 17˝ wide. The folder comes with a counter, speed control and optional batching.

Martin Yale's 959AF air-feed AutoFolder features individual vacuum and air pumps for more efficient feeding and lower operating costs. New rubber folding rollers are resistant to the chemicals in carbonless papers. A dual-surface sheet detector effectively doubles feeding life. Coated or printed stock feeds effortlessly through the 959AF at up to 18,000 sph. Bottom feeding means you never have to stop the machine to reload or reverse pre-numbered sheets. The 959AF can slit, score or perforate during folding.

Duplo's DF-520 automatic-setting tabletop folder has six preprogrammed folds and unlimited custom folds. Accurate folding for a variety of applications is accessed at the touch of a button. This folder requires no adjustment for paper thickness and accepts a range of paper sizes. The control panel displays programming and error messages at a glance, enhancing productivity.