Booklet Making machinery comes in all shapes and sizes from compact low volume desktop solutions to high end, high capacity booklet makers such as the Muller Martini or the Ferag range of machinery, both of which are used for the creation of some of the most common magazine and newspaper brands.
Probably the most common application for booklet makers is booklet production alongside a digital print engine for high quality, on demand booklets or magazines. Volumes of work tend to dictate the machinery requirement with high volume production from a lithographic press more suited to a Tower Collator fed unit into a stitch, fold and three knife trimmer. However, digital output is far more convenient and commonly produced in a collated sequence rather than individual sheets as a Lithographic press would produce. As a result of this style of output tied to the fact that most volumes of work are quite low for each production run and the common requirement for several different styles to be produced in any given day favours machinery that is either hand fed, such as our EB1000 & EB2000 or utilises a digital feeder, such as our Aeolus 52 which are able to feed materials in collated order.
Digital feeders are a variant of the traditional collator towers utilising vacuum feed technology to feed the materials through to the booklet making unit. However, unlike a traditional collator tower which takes singular sheets from each of the feed trays to create a single booklet set, a digital feeder is able to take multiple sheets from a single feed tray to create the booklet set from an already collated output. The advantage of this method is the fact that you can virtually start production from the first delivered output from your digital print engine whereas with a traditional lithographic output requires the entire job to be completed before booklet production can commence.
There are many different types of digital feeder currently available on the market with both single and double feed stations as well as full collator towers able to feed multiple sheets from each feed tray via special program functions. Further to this there are also digital feeders with integrated creasing and slitting which allows for three sided trim functions to be completed in two stages but removes the need for a guillotine in the production cycle.
Our range of Universal Feeders can be paired to our EB3000 booklet maker to enable an automated digital output friendly configuration. We offer three Universal Feeders, Aeolus Mini (Coming Soon), Aeolus 38 and Aeolus 52 which covers the range from desktop to high capacity free standing solutions, all of which can be programmed to feed singular or multiple sheets from any given stack. We are also producing a Universal Feeder with integrated crease and margin trimmers to enable a completely automated booklet solution with three knife trim and total bypass of the guillotine for speedy, easy production.
As the name suggests however our Universal Feeders are not simply for use with our range of Booklet Makers, they are universally compatible with other existing machinery from other manufacturers. This versatility allows these feeders to pair with existing laminating equipment, booklet makers, our Layflat WC515 Photo Book punch and KF Pro Knife folder as well as a host of other functions when tied with our range of conveyor bridge connections, the possibilities are endless.
Unlike many other booklet makers on the market which are aimed at the digital print sector which utilise staple heads or staple cartridges to bind the booklet our machinery all use high capacity Deluxe Stitch Heads with a further option to use Hohner Stitch heads if preferred.
The advantage of stitching heads is clear as all the higher volume machinery on the market use stitch heads and not staples due to the fact that a stitch is far stronger, more versatile in use and most importantly of all far lower cost to run. Two stitching wire spools cost around £28 + VAT and produce up to around 30,000 booklets, two cartridges which staple up to 5,000 booklets cost in the region of £32 + VAT, as you can see the difference in cost is huge and means stitch head machinery offers a far quicker return on investment.
On top of the cost advantages are the reliability of stitch heads over staple cartridge solutions, stitch heads are capable of producing millions of stitches with very little maintenance whereas most staple heads are recommended to be exchanged for each 250,000 cycles. Obviously the cost to replace the staple head, depending on type and brand, is far lower than replacing the Stitch Head but another advantage is the fact that stitch heads are made up of a number of parts, all of which are individually replaceable meaning you can simply exchange the worn part rather than the complete assembly which keeps the maintenance costs of your machinery low.
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