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Description
Built for large softcover book production runs, it binds at up to 12,000 cycles/h and reaches up to 24,000 books/h thanks to the inline splitting saw for double-utility (2-up) production. The line is equipped with 21 gathering stations with streamfeeders, 2 card gluing units, 2 spine and 1 side gluing station processing Hotmelt and PUR glue, a gauzing station, a long drying conveyor system, a three-knife trimmer, a stacker, and a palletizer — resulting in a continuous high-output workflow
Specifications
Equipment
Book Block Feeder
- Type: Meccanotecnica Fido, automatic
- Year of manufacture: 2012
Gathering Machine
- Type: Kolbus ZU 841.B
- Year of manufacture: 2012
- Application: For folded sheets and single sheets; flexible adaptation to the current customer job via interchangeable feeders
- Gathering Stations: 21 gathering stations, currently equipped with 15 streamfeeders (type STA 840, year of manufacture 2012)
- Card Inserters: 2x Kolbus KK 841 (year of manufacture 2012/2013)
- Reject Unit: Kolbus AS 841 (year of manufacture 2012)
- Setting-Up Shaft: Transfer chute connecting to the perfect binder, type KM 412.B
- Vibration Station: Integrated vibration/jogging stations
- Drive Technology: AC-drive synchronization; separate drives for transport chain and gathering stations
- Pneumatics: Air-Center for compressed air, vacuum and blow-air supply
- Control: Central TFT touchscreen (PRO-FACE) as main control station; central fault display via 7-segment indicator; countdown counter
- Product Flow: Left-hand travel into the binder
- Operator Access: Crossover with aluminium access ladders (ZARGES, 4-step) and aluminium handle
- Crane System: Gramatec/Demag crane rail, approx. 25 running metres, max. reach approx. 6 m, with 2 cranes, type CL 411 (year of manufacture 2019), max. load capacity 500 kg
Gathering Machine – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | 12,000 cycles/h |
| Format max | 320 x 510 mm / 12.6 x 20.1 in |
| Format min | 105 x 105 mm / 4.1 x 4.1 in |
| Pile Height max (Magazine / Transport Channel) | 250 mm / 80 mm — 9.8 in / 3.1 in |
| Feeding Height | approx. 820 mm / 32.3 in |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Perfect Binder
- Type: Kolbus KM 412.B
- Year of manufacture: 2016
- Control: Copilot system with touchscreen
- Number of Clamps: 30x transport clamps
- Infeed: Book block feeding station
Spine Preparation
- 1st Main Milling Station: Yes (chip milling head + dust milling head, wet-grind blade mount, suction-ready)
- 2nd Main Milling Station: Yes (chip milling head + dust milling head, wet-grind blade mount, suction-ready)
- Leveling Milling Station: Yes
- Notching Station: Yes (speed-controlled, removable brush insert)
- Micro-Notching Station: Yes (speed-controlled, removable brush insert)
- Brushing Station: Yes (roller brush)
- Gauzing Station: For processing gauzing materials and gauze
Spine Gluing
- Hotmelt (EVA): Spine glue unit with premelter Kolbus LH 375.C
- PUR: Spine glue unit, PUR
- Nordson Drum Melter: Type XNO 962, with 1 vacuum hood and 3 glue basins, feeding the PUR unit
Side Gluing
- Hotmelt (EVA): Side glue unit with premelter Kolbus LH 375.A
Cover Feeding
- Cover Feeder: Stream cover feeder, type SAL 413.B
- Creasing Station: For 4-fold creasing
Pressing
- Pressing Station: Nipping and pressing station
Perfect Binder – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | 12,000 cycles/h |
| Book Block Format max (W x H x T) | 320 x 510 x 80 mm / 12.6 x 20.1 x 3.1 in |
| Book Block Format min (W x H x T) | 100 x 105 x 3 mm / 3.9 x 4.1 x 0.1 in |
| Book Block Overhang min/max | 8 – 20 mm / 0.3 – 0.8 in |
| Transport Clamps | 30 |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Drying / Cooling Conveyor
- Type: Kolbus drying tower, approx. 200 x 220 cm footprint
- Conveyor: Approx. 60 running metres, with diverter switch, transferring book blocks from the binder to the trimming section
Splitting Saw
- Type: Kolbus TR 162
- Year of manufacture: 2015
- Application: For splitting double-utility perfect-bound or thread-sewn book blocks
- Conveyor: Approx. 3 running metres, with diverter switch, downstream of the splitting saw
Splitting Saw – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | double-utility 1,700–15,000 blocks/h / single-utility (equivalent) 3,400–30,000 blocks/h |
| Format max (uncut, double format) | 330 x 530 mm / 13 x 20.9 in |
| Format min (uncut, double format) | 80 x 200 mm / 3.1 x 7.9 in |
| Block Thickness | 5–80 mm / 0.2–3.1 in |
| Saw Blade Diameter / Thickness | 360 mm / 14.2 in — 2.2 mm / 0.09 in |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Three-Knife Trimmer
- Type: Kolbus HD 153.P
- Year of manufacture: 2012
- Application: For three-side trimming of book blocks and brochures
- Conveyor: Approx. 5 running metres, downstream of the trimmer
Three-Knife Trimmer – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max (magazine operation) | 6,600 cuts/h |
| Format max (cut) | 300 x 420 x 80 mm / 11.8 x 16.5 x 3.1 in |
| Format min (cut) | 100 x 120 x 1.5 mm / 3.9 x 4.7 x 0.06 in |
| Format max (uncut) | 310 x 430 x 80 mm / 12.2 x 16.9 x 3.1 in |
| Pressing Force max | 20 kN (stepless) |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Delivery and Stacking Line
- Destacker: Type AE 360, year of manufacture 2012
- Cross Stacker: Type XKL 500, for stacking book blocks, brochures and magazines
- Stack Aligner: With consolidator, type SR 500 A, year of manufacture 2012
- Conveyor: Approx. 17 running metres
Cross Stacker – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max (infeed) | 18,000 cycles/h |
| Format max | 320 x 420 x 80 mm / 12.6 x 16.5 x 3.1 in |
| Format min | 100 x 125 x 2 mm / 3.9 x 4.9 x 0.08 in |
| Stack Height max | 330 mm / 13 in |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Shrink Wrapper (Optional)
- Type: Shrink tunnel, approx. 200 cm, with 1 packaging unit, type SP 6030 W
Labeler (Optional)
- Type: Manufacturer WH, type Contact 100
Banding Machines (Optional)
- Type: 2x banding machine, manufacturer ATS, type US-2000TR
Palletizer
- Type: Kolbus PL 771
- Year of manufacture: 2012
- Control: 1 touchscreen control panel
- Pallet Magazine: Yes
Palletizer – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | 30 stacks/min (at ≤ 310 x 220 mm and min. 4 products per row) |
| Stack Format max | 563 x 406 x 350 mm / 22.2 x 16 x 13.8 in |
| Stack Format min | 150 x 100 x 25 mm / 5.9 x 3.9 x 1 in |
| Load Weight max | 1,500 kg/pallet |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
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