Specifications
Equipment
Gathering Machine
- Type: Kolbus ZU 842.E
- Gathering Stations: 12 gathering stations: 9x Standard Feeders + 3x Feeders for 5 mm Layers)
- Card Inserters: 2x Kolbus KK 842 (for cards, booklets, CDs in sleeves, samples)
- Signature Control: Sheet Recognition System (Kolbus Copilot design), camera-based, for 12 stations, image/text mode or barcode mode
- Thickness Control: Automatic sheet thickness control (ATC) on each feeder
- Setting-Up Shaft: With automatic block-thickness adjustment (connecting chute to perfect binder)
- Reject Unit: Kolbus AS 842.E (reject to the right)
- Vibration Station: Under-ventilated transport channel, extended vibration section (1,230 mm)
- Electrostatic Equipment: Restitution device for bundled signatures (3 electrodes); fixing device for advertising inserts (3 carriers)
- Drive Technology: Servo drive (Siemens SIMOTION D) with regenerative Active Line module
- Control: Touchscreen (Kolbus Copilot design)
Gathering Machine – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | 18,000 cycles/h |
| Format max | 320 × 360 mm / 12.6 × 14.2 in |
| Format min | 105 × 140 mm / 4.1 × 5.5 in |
| Pile Height max (Magazine / Transport Channel) | 250 mm / 60 mm — 9.8 in / 2.4 in |
| Feeding Height (incl. platform) | ca. 1,120 mm / 44.1 in |
Perfect Binder
- Type: Kolbus KM 412.E
- Control: Copilot system with touchscreen
- Number of Clamps: 40x, laterally swivelling
- Infeed: Horizontal infeed with vibration and rest section, coupled to gathering machine ZU 842.E
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)
Spine Gluing
- Hotmelt (EVA): 2x movable EVA hotmelt spine glue units with premelter Kolbus LH 375.C (160 l storage, up to 130 l/h) each
- Hotmelt (PUR), Exchange Unit: 1x exchangeable PUR hotmelt spine glue unit
- Nordson Drum Melter: Type XNO 962 (200 l steel drums, ~35 kg/h melting capacity), feeding the PUR unit
- Edge-Bead Device: Yes, for one hotmelt spine glue unit (edge-wrap gluing)
Side Gluing
- Hotmelt (EVA): 1x movable EVA hotmelt side glue unit with premelter Kolbus LH 375.A (90 l storage, up to 20 l/h)
Cover Feeding
- Cover Feeder: Stream cover feeder Kolbus SAL 413.E, top shingle-stream singulation, faulty/double-sheet control, folded-flap processing, cover recognition from below
- Creasing Station: For 4x creasing
Pressing & Delivery
- Pressing Stations: 2x, single-pass cover-to-block pressing
- IR Heating: In clamp deflection area (extends hotmelt open time)
- Delivery: Straight delivery (2,900 mm)
- Lay-Down Device: To the left, plate chain, laterally adjustable, automatic speed matching
Quality Control
- Inline control of block width/thickness/height and cover-to-block position, adjustable sensitivity, automatic individual-product ejection via switch gate
Perfect Binder – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max | 18,000 cycles/h |
| Book Block Format max (W × H × T) | 320 × 360 × 60 mm / 12.6 × 14.2 × 2.4 in |
| Book Block Format min (W × H × T) | 100 × 140 × 3 mm / 3.9 × 5.5 × 0.1 in |
| Binder Infeed Channel Width max | 80 mm / 3.1 in |
| Book Block Overhang min/max | 8 – 20 mm / 0.3 – 0.8 in |
| Cover Format max (total width) | 700 mm / 27.6 in |
| Cover Format min (total width) | 203 mm / 8.0 in |
| Cover Height min/max | 140 – 360 mm / 5.5 – 14.2 in |
Drying / Cooling Conveyor
- Type: Kolbus transport and cooling/drying section
Three-Knife Trimmer
- Type: Kolbus HD 153.P
- Control: Copilot system with touchscreen
- Infeed: Right infeed, with shingle-feed device for stack-counter operation (product thickness 2 – 5 mm, up to 15,000 pcs/h)
- Magazine Operation: Yes
- Cutting Tables: 12 one-piece tables (with pressing plates), block heights 160 – 304 mm in 12 mm increments
- Transport: Clamp (gripper) transport system
- Knife Setting Device: Yes
- Central Lubrication: Automatic
- Chip Removal: Blast nozzles at knife holders; prepared for central suction connection
- Drive Technology: Servo drive (Siemens SIMOTION D) with regenerative Active Line module
Three-Knife Trimmer – Technical Details
| Parameter | Value |
|---|---|
| Mechanical Speed max (magazine operation) | 6,600 cuts/h |
| Infeed max (single-block) | 12,000 pcs/h |
| Infeed max (shingle feed, magazine operation) | 20,000 pcs/h |
| Format max (cut) | 300 × 420 × 80 mm / 11.8 × 16.5 × 3.1 in |
| Format min (cut) | 100 × 120 × 1.5 mm / 3.9 × 4.7 × 0.06 in |
| Format max (uncut) | 310 × 430 × 80 mm / 12.2 × 16.9 × 3.1 in |
| Pressing Force max | 20 kN |
| Front Trim max | 40 mm / 1.6 in |
| Head/Foot Trim max | 50 mm / 2.0 in |
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