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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
- Automatic book block feeder, manufacturer Meccanotecnica, model Fido
- Year of manufacture 2012
Gathering Machine
- Kolbus gathering machine, type ZU 841.B
- Year of manufacture 2012
- For folded sheets and single sheets
- Flexible adaptation to the current customer job via interchangeable feeders
- 21 gathering stations
- 15 streamfeeders, type STA 840, year of manufacture 2012
- 2 card gluing units, type KK 841, year of manufacture 2012/2013
- PRO-FACE touchscreen control panel
- Transfer chute connecting to the binder, type KM 412.B
- AC-drive synchronization
- Central fault display via 7-segment indicator
- Central TFT touchscreen as main control station
- Countdown counter
- Separate drives for the transport chain and the gathering stations
- Integrated vibration/jogging stations
- Air-Center for compressed air, vacuum and blow-air supply
- Left-hand product travel into the binder
- Operator crossover with aluminium access ladders
- Crane rail, manufacturer Gramatec/Demag, approx. 25 running metres, max. reach approx. 6 m, with 2 cranes, type CL 411, year of manufacture 2019, max. load capacity 500 kg
Reject Unit
- Kolbus reject unit, type AS 841
- Year of manufacture 2012
Binder
- Kolbus perfect binder, type KM 412.B
- Year of manufacture 2016
- 30 transport clamp stations
- Copilot touchscreen control
- Book block feeding station
- Gauzing station for processing gauzing materials and gauze
- 2 milling stations
- 2 spine gluing stations, Hotmelt and PUR
- 1 side gluing station, Hotmelt
- 2x Nipping and pressing station
- Cover feeder, type SAL 413.B
- Creasing station for 4-fold creasing
Premelter / Additional Glue Unit
- Glue station, manufacturer Nordson/Kolbus, type XNO 962
- Year of manufacture 2012
- 1 vacuum hood
- 3 glue basins
Drying Conveyor
- Drying tower, approx. 200 x 220 cm footprint
- Conveyor system, approx. 60 running metres, with diverter switch, transferring book blocks from the binder to the trimming section
Splitting Saw
- Kolbus splitting saw, type TR 162
- Year of manufacture 2015
- For splitting double-utility perfect-bound or thread-sewn book blocks
- Conveyor system, approx. 3 running metres, with diverter switch, downstream of the splitting saw
Three Knife Trimmer
- Kolbus three-knife trimmer, type HD 153.P
- Year of manufacture 2012
- For three-side trimming of book blocks and brochures
- Conveyor system, approx. 5 running metres, downstream of the trimmer
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 system, approx. 17 running metres
Shrink Wrapper (Optional)
- Shrink tunnel, approx. 200 cm, with 1 packaging unit, type SP 6030 W
Labeler (Optional)
- Labeling machine, manufacturer WH, type Contact 100
Banding Machines (Optional)
- 2x banding machine, manufacturer ATS, type US-2000TR
Palletizer
- Kolbus palletizer, type PL 771
- Year of manufacture 2012
- 1 touchscreen control panel
- Pallet magazine
Auxiliary Equipment
- Compressor system, manufacturer Becker, type Variair/CS01330222ZU841, year of manufacture 2012, max. output 33 kW
Technical Details
Gathering Machine (ZU 841.B)
| Parameter | Value |
|---|---|
| Speed | up to 12,000 cycles/h |
| Format | max. 320 x 510 mm (12.6" x 20.1") / min. 105 x 105 mm (4.1" x 4.1") |
| Stack height | magazine max. 250 mm (9.8") / transport channel max. 80 mm (3.1") |
| Feed height | approx. 820 mm (32.3") |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Binder (KM 412.B)
| Parameter | Value |
|---|---|
| Speed | up to 12,000 cycles/h |
| Block format | max. 320 x 510 x 80 mm (12.6" x 20.1" x 3.1") / min. 100 x 105 x 3 mm (3.9" x 4.1" x 0.1") |
| Book block overhang after spine processing | min. 8 mm (0.3") / max. 20 mm (0.8") |
| Transport clamps | 30 |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Splitting Saw (TR 162)
| Parameter | Value |
|---|---|
| Speed | double-utility 1,700–15,000 blocks/h / single-utility (equivalent) 3,400–30,000 blocks/h |
| Format (uncut, double format) | max. 330 x 530 mm (13" x 20.9") / min. 80 x 200 mm (3.1" x 7.9") |
| Block thickness | 5–80 mm (0.2"–3.1") |
| Saw blade diameter / thickness | 360 mm (14.2") / 2.2 mm (0.09") |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Three Knife Trimmer (HD 153.P)
| Parameter | Value |
|---|---|
| Speed | up to 6,600 cuts/h (magazine operation) |
| Format, trimmed | max. 300 x 420 x 80 mm (11.8" x 16.5" x 3.1") / min. 100 x 120 x 1.5 mm (3.9" x 4.7" x 0.06") |
| Format, untrimmed | max. 310 x 430 x 80 mm (12.2" x 16.9" x 3.1") |
| Pressing force | max. 20 kN (stepless) |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Cross Stacker (XKL 500)
| Parameter | Value |
|---|---|
| Speed | up to 18,000 cycles/h (infeed) |
| Format | max. 320 x 420 x 80 mm (12.6" x 16.5" x 3.1") / min. 100 x 125 x 2 mm (3.9" x 4.9" x 0.08") |
| Stack height | max. 330 mm (13") |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
Palletizer (PL 771)
| Parameter | Value |
|---|---|
| Speed | up to 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") / min. 150 x 100 x 25 mm (5.9" x 3.9" x 1") |
| Load weight | max. 1,500 kg/pallet |
| Electricity | 3-phase, 400 V/N/PE, 50 Hz |
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