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Flexbook 4s

The system will convert a digitally printed web 42” (1066,8mm) wide web processing for 8 ribbons finished product into jogged, collated stacks and glued ready for the bindery. Fundamental design criteria for the system will be to allow for rapid changes in job setup.

 

SKU 0368974422-1-2-1 Categories , Tags , , ,

Overview

The system will convert a digitally printed web 42” (1066,8mm) wide web processing for 8 ribbons finished product into jogged, collated stacks and glued ready for the bindery. Fundamental design criteria for the system will be to allow for rapid changes in job setup. The system in general will:

  • Receive output from a roll-fed digital print engine
  • Align and tension the web
  • Slit the web into as many as 8 ribbons
  • Shift alternating ribbons to be on top of the previous ribbon. i.e. 2 on 1, 4 on 3, etc. and to create a gap between adjacent pairs of ribbons to aid in downstream jogging/gluing
  • Compensate length of ribbons to be in register one to another as is before shifted
  • Cut the two-ply ribbons to length in register to the pre-printed web
  • Stack and jog sheets into piles with an exact number of sheets as determined by a printed mark by the digital engine
  • Stack sheets will be pressed prior to being glued
  • Apply glue along one edge of a stack keep stack defined once combined with other stacks

Features

The system is comprised of 5 modules as follows:
  • Infeed/Slit Unit
  • Ribbon Shift and Compensator Unit
  • Sheeter Unit
  •  Batcher/Stacker/Compression/Gluer Unit
  • Book Block Accumulation and log bundle/receding stacker (option)
FLEXBOOK Integration Downstream:
  • Manual book blocks (loose) for spiral binding
  • Integration into digital bindery
  • Glued Book blocks – providing material handling and utilization of existing bindery
  • Infeed/Slit Unit:WiderWeb up to 42” (1066,8 mm) accepted:
  • Encoder (idler mounted in upstream equipment) provides speed reference
  • 12″ (305mm) Circ Tension Draw roll is servo-driven, with full width pneumatically operated rubber covered nip roll
Web aligned by “tilt-box” web guide Accuweb
  • Automatic Decurler
  • Crush Slitter station
  • Up to 7 Pneumatically loaded holders on 12″ (304,8mm) Circ hardened anvil cylinder
  • Anvil drive coupled to tension draw roll
  • Remote motorized slitter holder positioning system, with memory pre-sets, for quick make-ready
  • Inclusion of silicone applicator
  • Option for tear-out perf
Ribbon Shift and Compensator Unit:WiderWeb up to 42” (1066,8 mm) accepted:
  • Up to 8 turn bars 2.5″ (63,5mm) diameter, chrome-plated, air lubricated
  • Remote motorized turnbar positioning system, with memory pre-sets, for quick make-ready
  • Turn bars can either turn the web to the right or left, with the compensators out the back of the unit
  • Remote motorized compensator positioning system, with memory pre-sets, for quick make-ready with integrated
    ribbon alignment sensors
  • Operator side ribbon is a reference
  • Bends over/under idlers to be minimized once ribbons are on top of one another
  •  Inclusion of automated ribbon compensation system
Sheeter Unit:
  •  12″ Circ Tension Draw (304,8mm) roll is servo-driven, with full width pneumatically operated rubber covered nip roll
  • Knife cylinder is servo-driven
  •  Cut-off register is by using a contrast sensor to read pre-printed register mark
  • Cut-off register tolerance is +/- 0.015″ (+/- 0.38mm)
  • Knife cylinder circ depends on max/min cutoff lengths as given in “General Specs” above
  •  4 cutoff edges on knives for extra knife life
  • Inclusion of waste Divert Gate
  • Inclusion of waste conveyor system for Gear side delivery of the product
  • Job cut-off length is keyed-in on operator interface, and requires no physical changes on the sheeter
  •  2 around design is possible for smaller cut-offs
  •  Knife cylinder design is as per Magnum Roll Sheeter
  • Decurler for sheeter located in Infeed unit, upstream of slitters
  • Fast belt conveyor to create gap between sheets for downstream shingling
  • Fast belt conveyor employs upper and lower tapes as well as vacuum table
  • Shingle stream delivery to batcher with adjustable table height
Batcher/Stacker/Compression/Gluer Unit:
  • Exact batch sheet count assured by proprietary mechanism/system.
  • Batch counter with identification system reviewed formally with Buyer
  • Auto-Preset for width variation
  • Side and rear joggers with air facility
  •  Compression prior to gluing station
  • Gluing Stations with hotmelt adhesion with automated height adjustment
  • Belt Driven Accumulation zone
  • 90-degree Conveyor Feed System and Book Block Staging Area
  • Quality inspection system to determine length variation, top and bottom pages
Interface Specificationswith Inkjet master control:
  • Speed reference
  • E-Stop
  • Print-ready
  • Job description
  • Siemens PLC – with operator interface (HMI)
  • Internet Connectivity for remote diagnostics
Product Capabilities:
  • Single Copy Production – 4″ width (101,6mm) -12″ length (304,8mm)
Version of Stream Deliveries
  • 4 Stream Output – 4” x 7” (101,6 x 177,8mm) Mass Market/Pocketbook. Single Production Delivery (8 Ribbons) 42” web (1066,8mm)
  • 3.5 Stream Output – to utilize paper inventory – Single or 2 Up Production Delivery (7 Ribbons) Half Stream delivers complete book block on secondary cycles
  • 3 Stream Output – 4,5” – 6,5” (114,3mm- 165,1mm) width (dependent upon print engine width). Production Delivery Single or 2 Up (6 Ribbons)
  • 2.5 Stream Output – to utilize paper inventory – Single or 2 Up Production Delivery (5 Ribbons). Half Stream delivers complete book block on secondary cycles
  • 2 Stream Output – 7″ – 9″ (177,8mm- 228,6mm)
Initial Set Up Waste Tolerances:
  • Upon receiving print from print engine manufacturer and first book block cycles and closes the sheet wastegate.
  • Waste requirements will be 5 cycles for good copy for existing job recipes in HMI.
  • Waste requirements will be no more than 10 cycles for new job recipes in HMI.
Waste – Clearing Strategy:
  • The machine is designed to minimize waste requirements due to paper conversion or print engine issues or calibration requirements.
  • The inclusion of a waste divert sheet delivery mechanism with an incline conveyor will ensure minimal waste.
  • In all occasions upon stoppages – we will reconvene at Page One on a new book block.
Book Block Tolerances:
  • Page Width Variation – Ribbon Slitting – same accuracy as Offset Book Presses
  • Slitting inaccuracy only if set incorrectly: +/- .015″ (0.38mm)
  • Page Length Variation – Sheeter: +/- .015″ (0.38mm
  • Batcher accuracy to ensure quality, saleable production off of conventional binder:
    Width = +/- 0.4mm
    Length = +/- 0.6mm
Book Block (Glue Application) – Hot Melt:
  • Glue set time <7 seconds, providing no adhesion to other book blocks in bundles.
  • Glue band width 3 – 6mmwith thickness 0.3 – 0.7mm.
  • Programmable for page counts and number of glue band applications, based upon book block length to ensure stability.
Gluing System:
  • Nozzles with automatic adjustment
  • programmable width and thickness application
  • Automatic temperature controller on glue application
  • Glue system designed for 24-hour production environment
  • Glue controls conveniently located

Details

Web width (print engine)

42” (1066,8mm)

Web width (Min)

12” (304,8mm)

Substrate

Uncoated offset
Groundwood
Coated

Max calipre

0.006" (0.15mm), high bulk stock equating to 60# offset or a maximum of 105 gsm

Flexbook will accomidate

40#/.0032”/60 gsm, including 50#/.0048”/90gsm

Min calipre

0.003" or 0.076mm, equating to 30# offset, 37# newsprint or 48.8 gsm

Output

4 stream

Minimum cutoff length

Long Grain 6" (152,4mm)

Maximum cutoff length

Long Grain 12" (304,8mm)

Minimum ribbon width

4" (101,6mm)

Maximum ribbon width

101/4" (260mm)

Design speed (phase I)

800 fpm(243mpm)

Operating speed (phase I)

600 fpm(182mpm)

Design speed (phase 2)

Upgraded based upon paper stocks

Operating speed (phase 2)

Upgraded based upon paper stocks









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