A5 'portrait' - 148 x 210mm (spine) - booklet production with the IBIS Smart-binder

1.. Using a 320mm wide web - at web speeds up to about 90 m/min

The 320mm web is cut into sheets with a length circa 225mm. These 4-page sheets enter the Smart-binder (SB) infeed and the bar code on each sheet is read. Each sheet is accurately side-registered and the SB plow-folds each sheet down the center. ISG cold glue may be applied along the inside of each folded sheet (SB-3 only) and the sheets collect together on top of each other on the saddle (max approx 50 sheets, 200 pages, depending on paper weight).

If a separately-fed cover is needed, then this will feed automatically from the optional cover feeder CIF-102 and is folded on top of the inside sheets. Sheets are wire-stitched (if stitching is required), and 3-side trimmed to A5 size. Booklets may be stacked on the optional BSS-10 if required.

Note: each sheet contains 4 pages so each booklet must have a multiple of 4-pages.

2.. Using a 640mm wide web

If it is possible to print on a 640 web then this can be slit into two 320mm wide rolls and each roll moved to the finishing system and processed as in 1.. above.

3.. Using a 320mm wide web with the additional F-100 folder - web speeds up to 150 m/min

Eight page increments

The 320mm web is cut into sheets with a length circa 450mm by the web-cutter. These 8-page sheets then enter the F-100 folder where they are buckle-folded in half. A line of cold glue dots is applied to the center of each sheet if cold-glue bound booklets are needed. The folded sheets are fed into the Smart-binder (SB). The bar code on each sheet is read. Each sheet is accurately side-registered and the SB plow-folds each sheet down the center. ISG cold glue may be applied along the inside of each folded sheet (SB-3 only) if cold-glue bound booklets are needed, and the sheets collect together on top of each other on the saddle (max approx 20 sheets, 160 pages, depending on paper weight).

If a separately-fed cover is needed, then this will feed automatically from the optional cover feeder CIF-102 and is folded on top of the inside sheets. Sheets are wire-stitched (if stitching is required), and 3-side trimmed to A5 size. The SB trimmer head knife removes the head fold. Booklets may be stacked on the optional BSS-10 if required.

Note: each sheet contains 8 pages so each booklet must have a multiple of 8-pages.

4.. Using a circa 450 mm web with the additional RF-100 rotator/folder - web speeds up to 100 m/min

Eight page increments

The optional RF-100 may be added between the web cutter and the IBIS Smart-binder (SB). The circa 450 mm wide web is cut into sheets with length 320mm (4 pages printed on each side, ie 8-page sheets) by the web-cutter, which are fed into the RF-100. The RF-100 rotates each sheet by 90 degrees and a line of cold-glue dots is applied to the center of each sheet if cold-glue bound booklets are needed.The RF-100 buckle-folds each sheet in half and feeds these folded sheets into the SB infeed.

The bar code on each sheet is read. Each sheet is accurately side-registered and the SB plow-folds each sheet down the center. ISG cold-glue may be applied along the inside of each folded sheet (SB-3 only) if cold-glue bound booklets are needed, and the sheets collect together on top of each other on the saddle (max approx 20 sheets, 160 pages, depending on paper weight). The SB trimmer head knife removes the head fold.

Note: each sheet contains 8 pages so each booklet must have a multiple of 8-pages.

This solution is preferred if it is required to switch between A5 and A4 booklets (when producing A4 booklets then the RF-100 rotate and fold can be switched off so sheets pass straight through the folder). Both A4 and A5 can be produced from the same 440mm (or 450mm) wide web. However sheets can only be rotated reliably if the stock weight is above 65 gsm.

Video: A5 booklet production with RF‑100 Data sheet: RF‑100.

5.. Using a circa 450mm web using TUSDC-100 2-up 'sheet direction changer'

This solution has the advantage of enabling booklets to be made with 4-page sheets (rather than 8-page) using a 440mm (or 450mm) wide web. However it can only be used to produce A5 booklets (it does not allow A4 booklets to be produced from the web) and sheets can only be direction-changed reliably if the stock weight is above about 60 gsm. The web is slit down the middle and sheeted to produce 2 sheets, both sized circa 225 x 320mm, side-by-side which are separated slightly and then direction-changed by 90 degrees before entering the SB. The production process is then the same as option 1.

This option is paper weight dependent, please contact IBIS to discuss.

See video Data sheet: TUSDC‑100.

6.. Off-line production from an SB-095 or SB-097 sheet pile feeder

A sheet feed rate of 400 sheets/min is possible, depending on sheet size, paper weight and other variables)

Printed 4-page sheets size 320mm x circa 225mm are loaded into the SB-095 or SB-097 sheet pile-feeder which feeds from the top of the pile into the Smart-binder infeed. The bar code on each sheet is read and the sheet is side registered and center-plow folded. ISG cold-glue may be applied to each sheet if cold-glue bound booklets are required (SB-3 only) and the folded sheets collect together on top of each other on the saddle (max approx 50 sheets, 200 pages, depending on paper weight). If a separately-fed cover is needed, then this will feed automatically from the optional cover feeder CIF-102 and is folded on top of the inside sheets.

The sheets (and optional cover) are wire-stitched (if stitching is required), 3-side trimmed to A5 size and delivered in a shingled stream onto an indexing delivery conveyor. Booklets may be stacked using the optional BSS-10 stacker if required.

Note: each sheet contains 4 pages so each booklet must have a multiple of 4-pages.

Video: Smart‑binder fed from pile feeder Data sheet: SB‑095 Data sheet: SB‑097