Producing Extended Content Label (ECL) booklets

In-line Laser Tabbing system

An in-line laser 'tabbing' system is available to connect to the IBIS Smart-binder delivery conveyor. This automatically opens up the front cover, laser-cuts the front edge of the cover to create the required extended 'tabs' and cuts all the other pages to a shorter width so that only the 'tabs' remain extending on the front edge of the booklet. See item 5 below. Please contact IBIS for details.

The reason IBIS Smart-binders are used for ECL production

1. ISG cold glue binding

IBIS offer the Smart-binder with our unique and patented option ISG‑cold glue system

Cold-glue binding is essential for many ECLs, for example in the pharmaceutical labels. The use of conventional wire stitching is not an option for these label booklets.

The ISG cold-glue system is easier to use and maintain compared to wire stitch heads.

2. Lightweight paper stock

Most ECL label booklets must be produced using very lightweight paper stock in order to contain as much printed data as possible with the minimum number of pages.

The Smart-binder is unique in being able to handle paper sock weights as light at 38 gsm (25 lbs text).

3. Label Integrity

Each label must contain the correct data relating to the product to which it is attached. Each type of ECL label (for a specific product) may have an individual ID number in the printed bar code (or 2D Datamatrix code) on each sheet.

The Smart-binder reads these sheet codes and uses its sophisticated integrated sheet and booklet tracking system and sensors to monitor the status of each Label booklet and automatically reject any ‘bad’ booklets. The Smart-binder control PC retains log files containing production data relating to each booklet produced, or rejected. The production log files may be viewed externally with a network connection if required. If any booklets are missing on the delivery then these must be reprinted. The optional Smart‑data Analysis System SDA-100 assists with the upstream interface to enable this automatic reprinting of any missing Labels.

4. Small Format Sizes

Many ECL labels have a small format size because of the small dimensions of the product to which they are subsequently attached. For this reason the Smart-binder can be supplied with special modifications to reduce the minimum booklet width to 75mm (measured from the spine to the front edge).

Video of the Smart-binder producing75mm wide ECL labels

Very short spine lengths can be achieved very efficiently by printing multiple booklets together (multi-up). For example, six ECLs with a 2" spine length may be printed on a 12" long sheet. The resulting 12" long booklet is then split into the 6 individual booklets after exiting the Smart-binder. Note that booklets with spine lengths between 95 and 160mm may be produced 2-up without needing any further trimming, by using the optional Smart-binder Trimmer‑Center Knife

The additional Book Splitter Trimmer TP-100 may be added to the Smart-binder delivery to cut long booklets into multiple short booklets of any required length.

5. ECLs with tabs

Some ECLs require an extended 'tabs' on the front cover as shown below:

These extended tabs may be produced by connecting an in-line laser tabbing machine to the Smart-binder booklet delivery. This automatically opens up the front cover, laser-cuts the front edge of the cover to create the required extended ‘tabs’ and cuts all the other pages to a shorter width so that only the ‘tabs ‘ remain extending on the front edge of the booklet. Refer to IBIS for more details about this optional additional in-line tabbing system.

Alternatively, a pre-tabbed cover may be fed from the optional Smart-binder Cover Feeder providing that the stock weight is not too low. See video ECL booklets with a tab on front cover

Alternatively the additional Rosas tabbing machine may be added to the Smart-binder delivery to reduce the booklet width and cut tabs into the outside cover on one side.

6. High Reliability with Minimum Maintenance

Machine 'availability' (up-time) is of course important for all ECL label production. The Smart-binder is a very heavy-duty system designed to operate 24/7 with the minimum of maintenance and with the highest possibility reliability.

7. Ability to Change the Number of Pages on-the-Run

Some ECLs may need to be produced in very small job quantities. The Smart-binder allows the number of pages in the ECL to change between one job and the next without stopping, under bar-code control.