A guide to in-line stitching technology

A guide to
in-line stitching
technology
For newspaper and commercial web presses
1
7 For those not familiar with in-line stitching, we are talking
about the business of stapling publications together while they
are still being processed on a production line, at full production
speed - perfect for newspapers, inserts and commercial print.
In-line stitching
For a higher quality printed product
Newspapers and commercial print all around the world
are adopting the stitched format with great success,
having proven to be highly appreciated by both readers
and advertisers. The stapled product gives it that quality
look and feel of a magazine. It is easier to read and navigate on the go and provides improved space for editorial
creativity and more lucrative advertising opportunities.
For cost-efficient production and new revenues
For printers, stitching doesn’t only add value to the printed product, it offers a cost-effective way for a printing
operation to generate new revenue streams. Spare capacity can be used to print and stitch inserts, advertising
supplements, brochures and magazines at full production speed.
Stitching in-line at full press speed also offers a seamless way to move part of the finishing process right into
the press, achieving significant cost savings on the total
cost of production. The stitched product is complete
right off the press!
Your press can stitch!
Virtually any press can accommodate an in-line stitching solution. Thanks to the compact size of Tolerans’
series of stitchers, they can be adjusted to fit in even the
narrowest spaces of your current press.
One or several sections can be stitched in one print run.
3
reasons
to stitch
1. Happier readers rule
The most obvious and compelling reason to switch to a
stitched publication is the finished product provides an
improved reader experience. Research shows readers
prefer stapled products, since pages are neatly kept together creating a magazine-like format that is far more
accessible.
on the center spread. The advertiser can even have a
separate section of their own.
More often than not, an unstitched paper is ‘consumed’ by one reader and cast aside. A stitched paper
can be picked up and re-read by someone else. Stitched
papers simply reach more people - more readers equal
more eyeballs.
2. For a higher quality product
There is no doubt that a newspaper that stays intact offers a feeling of superior quality. It lasts longer, keeping
it fresh, easy to handle and refer back to at various times
of the day.
4. Stitched sections and inserts make
business sense
Readers have come to expect their newspaper to double
up as TV guide, a sports round-up, travel companion,
business brief and cultural diary, for example. These
distinct sections are often presented as weekend or daily
supplements in a compact format where stitching can
provide valuable advantages. Several sections can be
stitched in one print run, at full production speed. Distinct, stitched ‘magazine-like’ sections foster consumer
commitment among special-interest groups and advertisers can more accurately target their audience.
3. What advertisers want
Stitching provides greater design flexibility and expands
the variety of advertising options available. Double
spread ads can be offered throughout the paper, not only
5. Stitch for innovative layout and design
Stitching opens the door for new editorial opportunities.
The use of images and headlines make a bigger impact
across a double spread, which stays intact through stitching.
Daily Focus - the latest of South Korea’s free dailies to be stitched.
4
6. To be green
Unstitched products produce exponentially more litter.
When a product is stitched, there is only one item to
pick up and recycle. In addition, the steel staples are
readily accommodated by standard recycling systems
worldwide. Stitching strengthens brand image by
answering the newspaper industry’s call to follow the
three R’s: reduce, reuse, and recycle.
Stitching in-line
– a fast return on
investment for printers
Generates new revenue streams for printers
For printers, stitching doesn’t only add value to the
printed product, it provides a cost-effective way for a
printing operation to generate new revenue streams.
Printers can use any spare capacity to print and stitch
inserts, advertising supplements, brochures and magazines at full production speed.
For a cost-efficient printing production
Stitching in-line also offers one seamless way to move
part of the finishing process right into the press. Stitch
at full production speed and the products are completely
finished during the printing process, which minimizes
cost for transport and unnecessary storage.
Stitching in-line means you can reach significant cost
savings on the total production cost.
How much does it cost to stitch?
To stitch a newspaper or a commercial product in-line is
an affordable investment. It costs less than 40 euro cents
per 1,000 copies.
That covers total cost of ownership, which includes
investment in customized stitching equipment,
implementation and wire consumption. (Figures based
on: stitching one book, 250,000 copies per day).
5
Stitching possibilities
What type of stitched products can be produced with
in-line stitching?
This depends on your production capability, and the
technical possibilities. Consider what you want to stitch:
newspapers? Sections like sports, business etc? TV-guide?
Real estate insert? Commercial products?
Here are some of the most common solutions.
More examples can be found at www.tolerans.com.
Single wide press
STITCHERS
RUNNING
STRAIGHT
STITCHERS
RUNNING
STRAIGHT
Cylinder stitcher stitching
straight
What it does: stitches one
book in straight mode.
When it fits: when you want
to stitch one book in the
press.
STITCHERS
RUNNING
STRAIGHT
Stitching one book in
straight mode
What it does: ribbon stitches
one book in straight mode
When it fits: suitable when
you want to stitch one book
in the press in straight
mode.
STITCHERS
RUNNING
STRAIGHT
BROADSHEET
6
Stitching a tabloid section
in a tabloid or broadsheet
newspaper.
What it does: stitches two
tabloid sections or one tabloid section in a broadsheet
newspaper.
When it fits: suitable for one
or multiple stitched sections.
BROADSHEET
Cylinder stitcher
stitching in straight or
collect mode
(double round press)
What it does: stitches one
section in collect mode
or two sections in straight
mode. When it fits: when
you want to produce one
or two sections in the press
and want to have the possibility to run in either straight
or collect mode for higher
pagination.
Stitching one tabloid
section in a broadsheet
newspaper.
What it does: stitches one
tabloid section in a broadsheet newspaper
When it fits: suitable when
you want to have a stitched
tabloid section in a broadsheet directly from the press
without any work in the mailroom.
Double wide press
Cylinder stitching in
straight or collect mode.
What it does: stitches one
section in collect mode
or two sections in straight
mode.
When it fits: when you want
to produce one or two sections in the press and want
to have the possibility to run
in either straight or collect
mode for higher pagination.
STITCHERS
RUNNING
STRAIGHT
Stitching one section in
the main tabloid-sized
newspaper
What it does: delivers two
stitched sections from the
press
When it fits: suitable when
you want to produce two
separate stitched sections.
STITCHER
RUNNING
STRAIGHT
Stitching tabloid
sections in a broadsheet
newspaper.
What it does: stitches two
tabloid sections or one tabloid section in a broadsheet
newspaper.
When it fits: suitable for one
or multiple stitched sections.
STITCHERS
RUNNING
SKIP
STITCHERS
RUNNING
SKIP
Stitching three tabloid
sections in one print run
What it does: stitches three
tabloid sections in one print
run.
When it fits: suitable when
you want to stitch one main
section with high pagination
and two inner sections with
lower pagination.
Triple wide press
STITCHERS
RUNNING
STRAIGHT
Cylinder stitching one or
two tabloids in straight or
collect mode.
What it does: stitches one (in
collect mode) or two tabloids
(straight mode).
When it fits: for single or
double book formats over
multiple formers.
Stitching several tabloid
sections and the main
paper.
What it does: produces
multiple stitched sections.
When it fits: when you want
to produce more than two
stitched sections.
STITCHERS
RUNNING
STRAIGHT
Stitching tabloid sections
in a tabloid or broadsheet
newspaper
What it does: stitches
tabloid sections in a main
tabloid or broadsheet.
When it fits: Suitable for
multiple stitched sections.
STITCHERS
RUNNING
STRAIGHT
Stitching tabloid
sections in a tabloid or
broadsheet newspaper.
What it does: stitches two
tabloid sections in a main
tabloid or broadsheet
newspaper.
When it fits: suitable for one
or multiple stitched sections.
7
8
Tolerans
-for a worry-free
stitching process
Tolerans is the global leader in design and manufacturing
of advanced in-line stitching systems for the newspaper
and commercial printing industries. Since the first stitcher was installed in 1968, Tolerans has grown its business to 70 countries around the world and has installed
thousands of stitchers.
Committed to R&D
Being a strong player in the global printing industry, we
are setting standards worldwide with several patents
registered. In our R&D laboratory new ideas and innovations are constantly being evaluated in order to meet
future requirements, taking both quality and environmental impact of our products and services into careful
consideration. Drawing on this vast fund of research
knowledge and process know-how, we can provide
customers with extremely flexible, modular stitching
systems that run at full production speed with a minimum of operator involvement required.
We guarantee full support, courtesy of our customer
project managers, from the start of the project until
our after-sales service takes over following start-up. In
addition, we have a worldwide network of experienced
service technicians who are on call whenever you need
operational assistance.
Tolerans also offers a broad range of services as standard, including the fundamentals of training customer
operators in stitching technology. Full documentation
and customized manuals and wear part programs are
always provided and, should you prefer our team to undertake regular service and maintenance of the equipment, we can provide such services too.
Altogether, this is what makes us the world leader in
in-line stitching systems.
We fulfill your production promises
Tolerans’ mission is to ensure our customers enjoy a
completely worry-free stitching process. Apart from
delivering reliable stitching systems of the highest
quality, we ensure the whole installation process works
smoothly.
9
In-line stitching
– how it works
In-line stitchers can be installed in almost every kind of
web press, and in various configurations, depending on
the production needs and the technical possibilities.
Cross-web stitching
There are two types of in-line stitching machines for
cross-web stitching; ribbon stitchers that are placed
under the former board or anywhere there is a ribbon
passage in the press, and cylinder stitchers that stitch
against the folding cylinder in the press. The slimmest
ribbon stitcher is only 100mm high and fits in even the
narrowest spaces in the press.
What products can be stitched?
Whether they are newspapers, accompanying sections
or commercial products, the following formats can be
stitched at full press speed when cross-web stitching:
• Tabloid sized products
• A3
• Mini-Berliner
• A4 (in short grain presses)
One or several sections can be stitched in one print
run, either straight, or inserted in a broadsheet or
tabloid sized paper.
Ribbon stitchers are placed under
the former board or anywhere there
is a ribbon passage in the press.
Ribbon stitcher
Ribbon stitcher
Ribbon stitcher
A Cylinder stitcher stitches against
the folding cylinder in the press.
10
Cylinder stitcher
Producing staples when cross-web stitching
At full press speed the stitchers produce staples with
extreme accuracy and total control during the process.
1.
Lateral stitching
NEW!
For stitching quarter-folded products
and broadsheets
New to the market are in-line ribbon stitchers for
lateral stitching. These are perfect for stitching
broadsheets or quarter-folded products. The stitching is done along the web instead of cross-web.
Stitching quarter-folded products in-line is a far
more cost-efficient process than stitching them offline since it’s less time consuming.
What products can be stitched?
p Broadsheets
p Berliner-sized products
p Quarter-folded products
The wire is fed from spools and guided in to the stitcher. After feeding the
correct length of wire the wire is cut to the full length of the staple.
2.
When lateral stitching is performed on broadsheet products, the
stitcher is mounted with one cylinder on each side of the former
board.
The cut wire is formed into a u-shape. This is done when the wire is in a
fixed position and passes over the former wheel. After being formed, the
wire is pressed through the web stream to hit the clincher dies.
3.
When stitching quarter folded products, the stitcher is mounted
with one cylinder on each side of the conveyor belt between the
chopper folder and the main folder.
On hitting the clincher dies the legs of the staple are bent into a bow
shape and the staple is completed.
11
Tolerans in-line
stitching systems
SPEEDLINER® 2.0 - for a worry-free stitching process
Tolerans SPEEDLINER ribbon and cylinder stitching
systems have rapidly become the world’s most sold inline stitching systems on the market. They are modular,
reliable, and easy to install, maintain and operate. They
can be placed in almost every kind of web press and run
at full production speed without interfering with the
printing process. Depending on your needs the stitchers
can be designed either as shaftless or mechanically
driven. The smallest stitcher is only 100 mm high and
require little or no press modifications.
Tolerans in-line stitching systems
• Run at full production speed
• For cross-web or lateral stitching
• For all kinds of web presses
• Any web width
• Cylinder or ribbon stitching
• Shaftless or mechanically driven
• Straight or skip/collect mode
• Stitch 8-192 pages
• 2-4 stitching heads
• Optional: puncher for thumb-indexing
12
Modular for easy maintenance
Tolerans’ stitching systems are easy to operate and
maintain, minimizing downtime and thereby reducing
the cost of maintenance. And with a central grease
system that lubricates not only the cam but all major
bearings, they remain very reliable. Each cross-web stitching machine features a service cassette that includes
the stitching fork, the wire rest, and an easily removable
cutting/forming unit. This modular design allows users
to change wear parts without having to undertake any
manual adjustments.
The stitching machines are movable on rails, making
it easy to transport them for service and maintenance
and allowing greater access to the folder.
CompactStitch
Easier, smaller, cheaper
CompactStitch is an affordable in-line ribbon
stitching system specifically designed for printing operations that haven’t had the possibility to
incorporate in-line stitching before. It’s compact in
size, extremely easy to use, and the low investment
ensures a fast return on investment. A perfect solution for printers where only basic funtionality is
needed. For single installations only.
User-friendly and intuitive graphical
user interface. Built-in indicator that
monitors service intervals.
Easy-to-use control system
Tolerans stitchers include a customized, modular
control system based on standard components, with
remote-controlled functions and a color touch screen
for easy operation. The control unit features a built-in
indicator that monitors service intervals and contains
service instructions to facilitate maintenance.
A remote access enables Tolerans engineers to troubleshoot and upgrade your system without being on site.
The flexible design allows integration in most press
control systems on the market.
System overview
The ribbon stitcher is placed under the former board or anywhere
there is a ribbon passage in the press. Only 100 mm high it fits in
even the narrowest spaces, and requires no or little press modifications.
Ribbon stitcher
Cylinder stitcher
Stitcher trolley
Wire handling
system
Electrical
cabinet
The stitcher is equipped with an easy to use
control system. The compact touch screen is only
100 x 80 mm from where you manage the basic
functionalities.
Control panel
Thumb-indexing
An optional feature in
Tolerans’ stitchers is thumbindexing. The stitcher is
equipped with punchers on
the cylinder wheels, which
cut half-round holes in the
right margin of the paper,
making it convenient to pull
out each section with your
thumb. Stitching together
with thumb-indexing make it extremely easy to navigate
a newspaper with several sections.
The control system is extremely easy
to operate. It has a compact touch
screen from where you manage the
basic functionalities such as on/off, wire
on/off and circumferential adjustment.
13
Stitching wire
Staple dimensions
Tolerans stitchers are designed for production of 14mm
or 16mm staples. The corresponding wire diameters are
0.5, 0.6 and 0.7mm.
Newspaper print
Wire specifications
To ensure production safety and optimal performance,
we recommend the use of high-quality stitching wire
from major brand wire suppliers.
Specification of wire principal analysis:
C 0,08%
Mn 0,40 - 0,50%
P 0,030 - 0,040%
S 0,030 - 0,040%
Specification of mechanical analysis:
Rm 620 - 940 N/mm2
Dim +0/-0,02 mm
Using the largest coils possible is recommended in order
to minimize wire change intervals.
Commercial print
How many staples are produced from 100 kilos of wire?
Million Copies
Million Copies/100 kg Wire Spool
WireDiameter
14
Wire unwinding
DrumTop – for better wire control and fewer spool
changes
Tolerans’ DrumTop is a compact and lightweight
wire-feeding system that can be connected to wire
drums up to 300 kilos. The bigger size of the wire
drum means fewer spool changes and shorter
downtimes, which saves money and improves
productivity.
The cover is transparent to enable the user
to check that the wire is being fed accurately and to protect the wire from paper dust,
ensuring optimal stitching results. It can be
placed up to 15 meters from the stitcher. The
DrumTop measures the remaining amount of
stitching wire and an inductive sensor checks
the wire is unwound correctly. If the wire breaks
or ends, the feeding box stops pulling the wire.
It is designed to fit most wire drums available
on the market.
Spool holders – standard type of wire unwinders
The robust and reliable design of the spool holder in
the SPEEDLINER system allows simple and quick
handling of the wire spools. The system is designed to
handle wire spools in the following dimensions in its
standard design: 15 kilos, 25 kilos, 50 kilos, 75 kilos,
85 kilos and 100 kilos. The wire in-feed mechanism
contains an inductive sensor for detecting wire
end and indicates the remaining amount of
stitching wire. Disconnecting the wire tubes is
easy with quick connectors.
Service and support
Worldwide support
We aim to provide our customers with a worry-free stitching process. Therefore, we have gone the extra mile in
developing a worldwide network of experienced service
technicians who are on a call for customers. The various
stitching solutions offered by Tolerans include a broad
range of service and support.
Training and documentation
Training customer operators in stitching technology
is fundamental to that service, both on-site training at
customer premises as well as in-depth sessions at Tolerans’ headquarters. Full documentation and customized manuals for specific stitching solutions are always
provided.
Service program
We offer several types of service contracts, where our
service technicians make one or several visits per year
for preventative maintenance and machine cleaning.
We also replace pre-defined wear parts and test run the
stitcher in the press at full production speed. If you are a
frequent stitching user, we can design a service contract
that best suits your needs.
Remote support
Since the built-in control system has a remote connection via modem or Ethernet, we are able to resolve many
issues immediately regardless of geographical distance.
Simple-to-use wear and spare part program
To gain optimal performance and production safety
of the stitching system wear and spare parts need to
be replaced regularly. All systems are equipped with a
customized wear and spare part program that makes it
easier to know when, how and what to replace. The different wear part kits are designed to be replaced at certain interval points. The wear part kits enable quicker
replacements with less downtime and, where applicable,
all mechanical settings are pre-set when delivered.
The wear part kits are
designed to be replaced
at certain interval points.
They enable quicker
replacements with less
downtime and, where
applicable, the mechanical
settings are pre-set.
15
P.O. Box 669, SE-13526 Tyresö, SWEDEN. Phone: +46-8 448 70 30. Fax: +46-8 448 70 40.
info@tolerans.com www.tolerans.com
Service Support phone: +46 8 586 116 10, email: service@tolerans.com.
To get in touch with our worldwide network of sales and service partners, please visit www.tolerans.com