Buchstrasse
In large companies in the graphics industry there are so-called book streets , where books with high editions are efficiently produced by machine and can therefore be marketed cheaply. These coherent, cyclically coordinated binding lines consist of many individual machines in a cycle, each of which is operated, equipped and maintained by trained staff. The hanging station is the main machine on the book line.
The raw product
The raw sheets produced from the factory printing area are placed on pallets with serial numbers and delivered to the final production (industrial bookbinding ) already folded . In the case of small formats, you can also print for two up (double up), which shortens the entire workflow and makes it more economical.
Gathering machine
After printing, the gathering machine is used first . On this machine, the delivered pallets with the printed sheets are properly set up in the correct order and sorted and collated in the correct order using collation marks ; the entire inner part of a book or brochure is now completely contained. The cover that is still missing (paperback, simple cardboard) or the hard cover version is only carried out in the later mechanical processes.
Perfect binding
In the following adhesive binder , the book blocks are produced from the printed sheets that have now been compiled and correctly superimposed. In the first step, the individual blocks, with the spine facing down, are guided and trimmed by flexible transport rails over a milling machine . The resulting roughened back position is guided in the second step over rotating glue rolls which endlessly dispersion - or hot glue is provided (hot melt). After the adhesive binding, one speaks of the finished book block, but this is still missing the end trim and the cover protection. Depending on whether the book block subsequently receives a flexible cardboard envelope or a solid book cover, we speak of a perfect bound paperback or perfect bound hard cover .
Log saw
A block saw is required for already bound double-up book blocks, as these have to be separated first. It is important to ensure that the book blocks are of the same size and that the so-called cut is right-angled so that the block can be cut exactly. Then the separated blocks are transported to the three-knife trimmer.
Block feeder
In contrast to double-up blocks, single-ups are inserted directly and transported to the three-knife trimmer via an ejector . Normally, the feeder is clocked in such a way that, depending on the type of cut (single or double cut), it ejects one or two books and thus prevents the magazine of the three-knife trimmer from running empty.
Three-knife trimmer
In the three-knife trimmer, the blocks are trimmed from three sides (head, foot and front trim) so that the individual folded sheets are open and the book can be opened later. The blocks can also be cut twice in order to work gently on materials and machines. To do this, two blocks are placed on top of each other and then cut, but you always have to expect slight fluctuations with double cuts.
There are exceptions if the block is stamped in register (calendar, address books) or has a color cut . Most of the time, all pages are trimmed in the binding line and only have to be inserted by hand.
Ribbon inserting machine
The cut block is opened in one or two places in the tape inserter. With various techniques that will then sign ribbon threaded and then drawn to the block back to stick it.
Hanging station
The hanging station is the main machine on the book line. The block runs in and the back glue is heated on the heater so that the block can later be rounded better. Then the block comes into the round station and is pushed up from below over a round iron and thus rounded. The book block is then pressed and a mushroom is formed on the spine, which is required for branding. Now the tape is glued on. For this purpose, a thin layer of glue is applied to the back and the drawing tape is glued on using compressed air and a scraper. Two capital stations now follow. The first sticks a piece of gauze on the back, which is stuck by the glue of the drawing tape. The second glued back again and stuck the stuck already on crepe paper head band on the block. Now the actual hanging follows. For this purpose, glue is applied to the front and back of the book block and the block is hung from bottom to top in the ceiling. Slight deviations can cause the block to hang at an angle, uneven edges or even a difficult stop of the machine.
Press / fold burning station
Here the hung book is pressed off in order to connect the cover and the block cleanly. In addition, a fold can be burned in, which aims to increase durability and embellish the book.
Labeler
Here a label is stuck on the book. The labeler can be used in different places: after the press, after a forklift or after the sealing machine, depending on how the label should be attached to the book.
Book stacker
A book stacker is used to stack books or, if necessary, to turn them over, for example for labeling or sealing. It has several programmable stacking options.
Dust jacket machine
In the dust jacket machine, the cover and bottom of the book are opened and a dust jacket is folded over. Some dust jackets cannot be folded at all or only with great difficulty with the dust jacket machine, because they are either too thin or too big or always have to fit exactly.
Welding machine
The sealing machine seals the books individually or in packages. Two swords put the books in a plastic tube and are then separated from each other with a hot knife. Then the wrapped book is transported through an oven, which shrinks the film and seals the book in a watertight manner.