IBIS Bindery Systems

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• IBIS Bindery Systems

Smart-binder system
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IBIS head office, London UK
IBIS background
Other staff
IBIS
Harris Graphics
AM Graphics
Heidelberg Finishing
1960 1988 1996 May 1999 2007

• IBIS was formed in May 1999 by Managers and
  Engineers previously with Harris, AM and
  Heidelberg
• We are a Privately-owned, independent UK-based
  business.
• Over 200 man-years collective experience in book
  finishing equipment design and manufacture.
• Sales partnership with all major digital printer
  vendors worldwide and CP Bourg Inc, USA
• Smart-binder is first choice in-line
  saddle-finishing solution for CF digital print
  and can produce both wire- stitched and glued
  books from the same machine.
• 100 focus on document finishing with CF printers
  - we are dedicated experts in this field and
  have a proven track record in providing
  customized solutions where needed.

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IBIS company structure
Vacuumatic, Colchester, UK IBIS Product
manufacture
World wide Distributor network (Digital printer
vendors, Pre/post vendors etc)

• IBIS head office
• (High Wycombe UK )
• Engineering Design
• Customer Service
• Administration

IBIS USA sales office
Product test and Demonstration center High
Wycombe UK
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IBIS Management Board

• IBISs senior management team and founding
  partners comprise
• three Oxford and Cambridge Engineering Graduates
  
• Malcolm Allitt (Non-exec Chairman) Formerly
  chief executive of Babcock
• division and senior roles with other
  international engineering companies
• John Cracknell (Managing Director) 20 years
  previous
• experience as Engineering Director with
  Heidelberg, AM
• and Harris.
• Mark Firth (Engineering Director) 20 years
• experience of designing special purpose and book-
• binding machinery.
• .

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Purpose and values

• Our Purpose
• To bring new opportunities and commercial
  advantage to our customers
• Our Values
• Openness
• We communicate honestly and frankly with both
  ourselves and with others.
•   Integrity
• We conduct ourselves correctly and deliver what
  we promise at all times.
• Technical excellence
• We take pride in supplying solutions with high
  standards of engineering and which provide
  maximum benefits to end-users.
•   Commitment
• We are committed to bringing success to our
  customers.
• .

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Product HistoryDrupa 2000 Digi-stitcher
DST2 launched2001 2005 55 DST2s sold
(mainly in-line with Oce and IBM printers)
Drupa 2004 Smart-binder models SB1, 2, 3
and 4 launched 2005 2007 45 Smart-binder
systems sold (in-line with most types of CF
printers, and off-line)
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Smart-binder SB-3 system (for in-line operation)
ISG cold gluing (optional)
Sheet and cover collector
Stitcher
Optional cover feeder
Folder
3-side trimmer
Finished booklet output
Sheet input from web cutter or off-line
pile-feeder
Reject bin

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Smart-binder typical in-line system configuration
Smart-binder system
CF Printer(s)
Web Cutter
Unwinder
Optional sheet pile feeder for off-line operation
Optional folder for very high speed or small
format books
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Typical in-line Smart-binder system configuration
Printed web (direct from printer or roll
unwinder)
Sheets entering the Smart-binder
Optional roller table (to change direction of
sheet entering from off-line feeder
Wire stitcher (with 2 stitch heads)
ISG cold-gluing (optional)
Folder
Sheet collector
Optional Cover feeder
Web Cutter
Trim-off removal
Three-side trimmer
Web feed rate up to 300 ft/min max (or higher
with extra folder)
Optional off-line sheet feeder on the side
(option SB-096)
Finished book delivery
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Off-line Smart-binder configurations
Sheet Stacker (part of upstream digital printing
system)
ISG cold-gluing (optional)
Optional Cover feeder
Wire stitcher
Folder
Sheet collector
Optional pile loading trolley
Three-side trimmer
Trim-off removal
Off-line sheet feeder
Folder
Sheet collector
Finished book delivery
ISG cold-gluing (optional)
Roll unwinder
Web cutter
Wire stitcher
Optional Cover feeder
Three-side trimmer
Finished book delivery
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In-line IBIS Smart-binder

• 1) High speed in-line operation. The
  Smart-binder is the only saddle-binding system
  designed specifically for in-line operation with
  highest speed digital web printers. Input web
  speeds up to 300 ft/min (or higher with extra
  folder). The Smart-binder is a proven solution
  in-line with most high speed CF printers.
• No manual paper handling. Sheets flow directly
  from the web cutter into the Smart-binder. Books
  are produced immediately the printer starts
  printing.
• No need to stack down sheets and manually load
  into an off-line feeder.
• Off-line Sheet feeding option. Sheets may be fed
  from the side to allow for off-line operation (if
  needed). Changeover between in-line and off-line
  operation is very fast.
• 4) Dynamic thickness change. Booklets with
  variable page count can be produced sequentially
  without stopping the system. Enables
  customised/personalised content (job runs of
  one).

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In-line IBIS Smart-binder (continued)

• 5) High productivity with minimum of
  operator set- ups.
• 6) Book integrity. Bar-code readers and
  sensors track each individual sheet. Bad books
  are automatically rejected.
• Very heavy duty design 24 x 7 operation with
  minimum maintenance and down-time
• Exceptional finished book quality Individual
  sheet folding results in very high fold quality,
  excellent finished-book appearance and lay-flat.
  Maximum book thickness up to 200 pages (160 pages
  recommended for optimum quality)
• Three-side trimming for perfect finished-book
  edges.
• ISG cold gluing Saddle-bound books may be made
  with either wire stitches or ISG cold glue. ISG
  cold-glued books are stronger and lay flatter
  than wire stapled books (higher-quality
  appearance).
• Large range of available options Sheet
  perforating, hole punching and drilling, off-line
  side feeding, book stacking, loop stitching,
  hot-melt gluing, post-trimmer folding document
  folding, center-knife cutting etc.

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Typical Smart-binder Applications

• Personalised documents (or any very short-run
  jobs)
• Time critical documents (where finished books are
  required as quickly as possible after receipt of
  print files) .
• Legal and financial documents.
• Government Papers.
• Health care plans and Insurance policies.
  
• Examination papers.
• Product manuals
• Sheet music
• CD and DVD booklets.
• Short-run magazines (eg low volumes samples to
  test consumer feedback)
• Sporting event programmes
• Etc.

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Gold-Service support

• IBISs Gold Service installation and support
  package comprises
• Machine packing and transportation to the end
  -customer.
• System Installation at the end-customer.
• Training for machine operators (and for
  maintenance engineers if needed) .
• Extended 12-month parts warranty.
• Completion of the pre-agreed production tests.
• Post-installation support to ensure continued
  performance.

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What you can expect

• We promise to
• Act with openness and integrity
• Respond to all communications within one
  working day.
• Treat with confidence all information you give
  us.
• Only sell to you if we are confident that we
  can meet you requirements.
• Review how our equipment may be customised to
  suit you needs.
• Test and demonstrate your job on our machine
  pre-sale, if felt necessary.
• Continue to work with you after installation
  until you are achieving the pre-agreed
• system performance.
• Provide you with continued access to our
  in-house technical support in future.

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IBIS Customer base
Europe

N.America
Japan
Taiwan
Malaysia
Africa
100 IBIS systems sold world-wide - 70 are
in-line with digital web printers. 30 are
off-line.
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Smart-binders at customers and exhibitions
Ipex with Delphax
Drupa with Oce
With Kern post-processing
Pindar UK (with Oce and Hunkeler)
Drupa with Xerox
Off-line (in Canada )
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Smart-binders at International Trade Exhibitions
(2004 2007)
With Océ, Kern and Xerox at Drupa, Duesseldorf
In-Line With Xerox at Graph Expo , Chicago
In-Line With Shoei at IGAS, Tokyo Off-line Oce
Open House In-Line With Xeikon at On-Demand
Philadelphia In-Line With Wifac at Grafivak,
Amsterdam Off-line With Xerox at Print 05 ,
Chicago In-Line Oce Open House In-Line With
Xerox, Delphax and Xeikon at Ipex In-Line With
Delphax at On Demand , Philadelphia) In-Line
With Oce at Graph Expo , Chicago In-Line Oce
Open House Off-line With CP Bourg at On Demand,
Boston Off-line With CP Bourg at Graph Expo ,
Chicago) Off-line With Sakata Inx at IGAS,
Tokyo. Off-line
2004
2005
2006
2007
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Customer Testimonials
RR Donnelleys, Lancaster, PA, USA We've been
using our Digi-stitcher DST2 heavily for the past
four years. We are coming off one of our peaks
where we produced over 500,000 books with pages
ranging between 16 and 128. Each of these books
are variable in nature in that every page is
different and every book has a different page
count. We are now in the process of looking to
purchase a second IBIS line. Randy Zercher,
Digital print supervisor, RR Donnelleys, USA
R V, Germany R V produce large numbers of
individually personalised insurance documents,
each up to 128 pages thick. These are made using
the Smart-binder SB-3s unique ISG cold gluing
system which offers many advantages over wire
stitching for this application. Covers with a
cut-out window are fed selectively from a
multiple-bin feeder. According to print manager,
Mr Hees, the system performs trouble-free . ...
Christof Hees, print manager, R V insurance,
Germany.
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Common Smart-Binder Options

• Hole Punching and Drilling
• HPM-100 Hole punch module for books up to 4mm
  thick
• HDM-100 Hole drilling for books over 4mm thick.
  
• Dynamic micro perforator
• DMP-100 Use to add lines of perforation holes
  'on demand' to each sheet parallel to fold line
  (to allow sheets to be easily torn out of the
  finished book)
• Double cover/insert system
• CF-100 Use to feed covers or insert sheets
• CF-101 Use to feed a second cover or insert
  sheet (only in combination with CF-100). This
  feature may also allow covers to change
  automatically from one feeder to the other, under
  bar-code control. Includes special control
  software.
• Cover feeder bar code reader BCR-100 for
  matching personalised covers with content sheets
• Loop stitch head and clincher LST-100
• May be used to produce 'loop' stitches
• Rotator/ folder RF100 for producing small
  format books in-line with web printers
• Folder F-100 for web speeds above 90 m/min (300
  ft/min)

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ISG cold-glued booklets

• The patented ISG (Individual Sheet Gluing)
  system applies a carefully controlled line of
  cold glue dots accurately on the inside fold
  line of each sheet, and the outside cover, before
  the sheets are collected, pressed together and
  three-side trimmed. Advantages of the ISG process
  over conventional wire stapling are
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• Higher page pull strength on the outer and inner
  sheets
• Tighter fold, particularly on thicker books.
  This is because wire stapling tends to open up
  the book.
• Cold-glued books can be recycled more easily than
  books containing wire staples.
• Glue binding avoids any child safety issues
  relating to the edges of wire staples.
• Glued books can sometimes be mailed directly,
  unlike wire-stapled books.
• The ISG gluing process requires no adjustment
  when the book format or thickness changes.

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ISG cold-gluing
Glue nozzle
No visible bind method
Outer sheet opened
Very tight fold
ISG glue dots between sheets (not visible to end
user)

• Improved fold quality- better lay-flat
• Easier to use lower maintenance, automatic
  adjustment
• Easier to recycle
• Consumable cost similar to wire-stitching

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Sheet perforation option (DMP-100)
Line of perforations to allow sheet to be easily
torn-out. May be applied selectively to
specific sheets only, under automatic bar-code
control.
 
The addition of this module increases the machine
length by 325mm
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Dynamic sheet perforation (option DMP-100)
325mm additional length
Sheet infeed from web cutter
Independent perforator rotary knife actuators
(pneumatic require HP air)
Smart-binder
Infeed register conveyor
DMP-100 dynamic micro-perforator option
Perforated sheets delivered to the Smart-binder
folder
Sheets arriving from the Smart-binder infeed
register conveyor
Typical Perforation line position
Lower sheet support roller
Sheet drive nip rollers
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Smart Binders With Colour Digital Printers

• Colour printers are generally slower than b w
  printers.  For this reason the lower cost
  Smart-binder model SB-1 may be used (if sheet
  input rates are less than about 120 sheets/min).
• The Smart-binder uses a bar code on each sheet
  for maximum page sequence security.  If this bar
  code is printed in colour instead of bw, then
  the optional laser reader may be selected to read
  these colour codes, instead of the standard
  Smart-binder CCD reader.  
• Colour toner is thicker and therefore more prone
  to cracking than black toner. The sheet scoring
  system on the Smart-binder must be specifically
  set to minimise cracking and the pressure between
  the folder nip wheels may be slightly reduced.
• Colour-printed books are more expensive and
  higher quality than b w printed books.  For
  this reason the extra quality provided by the
  Smart-binder (tighter sheet fold, more accurate
  stitching, option for cold-gluing and 3-side
  trimming) becomes more important and needed.
• Colour printed sheets tend not to be so absorbent
  as b w printed sheets.  For this reason , when
  using ISG cold glue instead of wire staples
  (which is desirable because of the increased book
  quality) the SB is able to apply a continuous
  line of glue (instead of dots) to increase bond
  strength.

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Contacts
IBIS USA Sales Contact (sales) Don
Piontek Phone [phone] cell. 952-239-2999
Address 14116 Westridge Drive Eden Prairie,
MN 55347-1732, USA.e-mail don.piontek_at_ibis-bind
ery.com
IBIS Ltd. UK Head Office Contact (Sales)
John Cracknell (Customer support) Martin
Reed Phone [phone] Address Unit 7,
York Way, Cressex Business Park, High Wycombe ,
UK. E mail sales_at_ibis-bindery.com
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• IBIS Bindery Systems
• www.ibis-bindery.com