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The production of school notebooks is an example of a healthy and profitable business. Making simple notebooks What equipment was used to make the notebook

Making simple notebooks

Question number 1. List the main steps in the manufacture of simple notebooks. Sheet colliding technology and factors affecting colliding accuracy and performance.

Making simple notebooks

Block diagram of TBPP editions in the cover

Block diagram of TBPP hardcover editions

The nomenclature of processing sheet printed products into book publications, including finishing and binding processes, contains more than 70 different operations necessary to turn prints into a packaging unit for the main products of book printing houses. Depending on the volume, design, level of artistic and printing design, requirements for strength and durability, the number and composition of operations can vary significantly, but all of them can be grouped into seven or eight complexes of sequential operations, which at a certain stage, in the presence of source materials and touched semi-finished products, can be performed independently. At large printing enterprises, in order to improve the organization of production, these complexes are separated into workshops or departments of a large workshop, and in the textbook they are grouped into sections, which contributes to the assimilation of the content of the TBPP discipline and the very concept of "technology": this is not only a set of processing methods, changes in properties and forms of material or semi-finished product in the production process, but also a strict list and sequence of operations, withdrawal and rearrangement, which can lead to the loss of important consumer properties of the product, and in the binding processes - book publication.

Completing a book block not from separate sheets, but from notebooks is not only a tribute to the old technology of binding handwritten and early printed books, but also a technological necessity. The production of books assembled from notebooks, and not from separate sheets (shares), makes it possible to reduce labor intensity and the likelihood of errors when assembling a block, to choose a method of its fastening and processing, ensuring good openness, high strength and durability of the book. It is technologically and economically expedient to make book blocks from 32-, 16- and 8-page so-called simple notebooks, obtained respectively with four-, three- and two-fold perpendicular symmetrical folding, as this ensures minimal time and labor costs in manufacturing operations blocks, high strength of sewing binding and good quality of mechanical processing of the spine, full use of the technological capabilities of printing machines and minimal costs in prepress processes, allows you to get the maximum strength and durability of books.

The production of simple book notebooks from prints obtained on sheet-fed printing machines includes the operations of colliding, trimming, and cutting sheets into parts, folding, pressing and binding notebooks and storing them until all structural parts of the book block are ready for further processing.

Sheet collision

Alignment of the edges of various sheet materials and prints on two adjacent ends of the foot is performed in order to increase the reliability of the feeders of printing, finishing and folding machines and the quality of products of single-knife paper-cutting machines. It is necessary in cases where the shift of sheets in a stack due to inaccurate operation of the take-up device of sheet-cutting and sheet-fed printing machines or careless transportation exceeds the tolerances for the amount of shift of sheets for the smooth operation of feeders, for the format and accuracy of cutting sheet materials and products. Unprinted paper, prints and various sheet binding materials are collided before printing, finishing, cutting and folding.

Push technology

Sheets are collided manually, on colliding semi-automatic machines and on automated integrated systems, which include a colliding machine. Pushing sheets manually is performed on a horizontal table with a flat and smooth surface, the width of which is somewhat greater than the diagonal of the sheets being processed. With manual pushing, the worker transfers a small (convenient to work) stack of sheets from the pallet to the pushing table, forms an “air lubricant” between the sheets of the stack with special techniques, spreads the stack with a “ladder”, aligns it with soft blows on the table surface alternately along the edges of the right angle, after pushing the air between the sheets with the palm of his hand and placing the stack on the feeder table, cutting machine, or other pallet. On a collided foot, the correct edges are marked with a colored pencil or, if the paper is intended for printing covers and postcards, by cutting off the right corner up to 10 mm from its top. When sealing the front side of the sheet, the right angle is marked with a special mark - a narrow strip up to 3 square meters long. on the side of the sheet. The marks in the stack form a clearly visible stripe on the end face.

With manual pushing, the labor of the worker is heavy and unproductive: he lifts and lowers each stack of paper to the surface of the table from 2 to 6 times, processing up to 4 tons of paper per shift. In small and medium-sized printing enterprises, simple-designed and affordable collating machines are used for colliding. Such a machine has a massive base, a table with two low walls-stops, a sheet blowing system and an electric drive that ensures the vibration of the table during the collision. During operation, the table occupies an inclined position, and the sheets, thanks to air lubrication and their own gravity, are aligned on side walls. The loading of the pusher machine should be done in small stacks, since with a large mass of the stack, the sheet blowing efficiency is significantly reduced, and the time for aligning the sheets along the side walls increases. Modern medium and large printing companies use automated complex systems that serve the processes of pushing, cutting and all related transfer operations.

After colliding, sheets of paper and prints should be counted and stacked in stacks of 500 copies on pallets in stacks whose height should not exceed 1.6 m. Stacks should be separated from each other by strips of colored paper to assess the amount of work performed and the amount of paper available or semi-finished products.

Paper and semi-finished products after colliding are evaluated by a single quality indicator - colliding accuracy. The sheets in the stack must be exactly aligned, with a tolerance of 3 mm for paper and 4 mm for binding cloth. The accuracy of the collision is determined visually when the foot is "pumped" along the correct edges.

Factors affecting colliding accuracy and performance

Accuracy and productivity of manual and machine colliding of sheets depends on the format, surface density, bulk density, smoothness and moisture content of the paper, as well as on medium size the initial offset of the sheets and the state of their edges.

Sheets of large format are less convenient to work with and, other things being equal, have a large mass, therefore, a stack of paper with a smaller number of sheets is taken for pushing than with medium and small format. The colliding performance is reduced by 17-20%. Paper with a high surface density, other things being equal, has a higher mass, thickness and stiffness, which has a twofold effect on the complexity of the operation: on the one hand, it is necessary to push stacks of paper with a smaller number of sheets, but, on the other hand, thick and rigid sheets of paper are relatively edges are easily aligned. For these reasons, for every 20% increase in paper basis weight, the jogging performance of paper over 90 g/m2 decreases by about 5%. Colliding sheets of thin types of paper with a low surface density is difficult due to their low rigidity. When aligning sheets on a hard surface of a table or the walls of a pushing machine, the probability of crushing their edges increases significantly. With this in mind, the production rates per collision of paper with a basis weight below 55 g/m2 are reduced by about 17%. Thin types of paper with a low surface density (for example, cigarette paper with a surface density of 16 g / m2) cannot be collided at all; they are leveled by pinning each sheet onto needles.

Sheets of calendered and coated paper with high smoothness slide well over each other and collide easily. High-calendered paper with a smoothness of more than 300 s and coated paper before trimming and cutting can not be pushed at all, but aligned by pushing it to the feeder and stop when laying the stack on the table of a single-knife paper-cutting machine.

The increased humidity of the paper makes it difficult to collide, as this reduces its rigidity and increases the coefficient of friction. At low (less than 5%) humidity, paper is easily electrified by close contact and friction of the sheets. The accumulation of charges during electrification leads to sticking of the sheets, which makes it difficult to perform basic colliding operations. The optimal moisture content of paper for this technological process, equal to 7-8%, can be achieved at normal relative humidity in the workshop (60 ± 5)% and after acclimatization of the paper for a day.

Large initial shift of sheets, wavy, wrinkled and damaged sheet edges make it difficult to collide. At the same time, when loading flat pile feeders of printing, finishing and folding machines, collisions may not be performed if the initial sheet shift does not exceed 3 mm. When loading round pile feeders of folding machines, collisions can be avoided even with a larger (up to 10 mm) offset of the edges of the sheets.

Question number 2. To characterize and describe the technology of manual picking and picking processes.

Making book blocks

The production of book blocks means two operations - the assembly of blocks and their fastening, but these are the key, most important operations in the technology of stitching and binding processes, since the quality of their execution to the highest degree determines the main consumer properties book-type publications: ease of use and the required durability.

Completing blocks with a tab (notebook in a notebook) is used in the manufacture of small-volume book publications - “thin” magazines for various reader purposes, books for children of preschool and primary school age, technological instructions for individual operations, various documents (membership cards, record books, etc. .) and white goods. The volume of such publications and products usually does not exceed 128 pages, and the block thickness is 6.5 mm. The thickness of the book block when assembling with an inlay is limited because the width of the outer shares of the paper sheet after cutting the block or publishing when bending the inner shares along the radius R (Fig. 5.1) decreases by an amount l proportional to the thickness of the block.

Question number 1. List the main steps in the manufacture of simple notebooks. Sheet colliding technology and factors affecting colliding accuracy and performance.

Making simple notebooks

Block diagram of TBPP editions in the cover

Block diagram of TBPP hardcover editions

The nomenclature of processing sheet printed products into book publications, including finishing and binding processes, contains more than 70 different operations necessary to turn prints into a packaging unit for the main products of book printing houses. Depending on the volume, design, level of artistic and printing design, requirements for strength and durability, the number and composition of operations can vary significantly, but all of them can be grouped into seven or eight complexes of sequential operations, which at a certain stage, in the presence of source materials and touched semi-finished products, can be performed independently. At large printing enterprises, in order to improve the organization of production, these complexes are separated into workshops or departments of a large workshop, and in the textbook they are grouped into sections, which contributes to the assimilation of the content of the TBPP discipline and the very concept of "technology": this is not only a set of processing methods, changes in properties and forms of material or semi-finished product in the production process, but also a strict list and sequence of operations, withdrawal and rearrangement, which can lead to the loss of important consumer properties of the product, and in the binding processes - book publication.

Completing a book block not from separate sheets, but from notebooks is not only a tribute to the old technology of binding handwritten and early printed books, but also a technological necessity. The production of books assembled from notebooks, and not from separate sheets (shares), makes it possible to reduce labor intensity and the likelihood of errors when assembling a block, to choose a method of its fastening and processing, ensuring good openness, high strength and durability of the book. It is technologically and economically expedient to make book blocks from 32-, 16- and 8-page so-called simple notebooks, obtained respectively with four-, three- and two-fold perpendicular symmetrical folding, as this ensures minimal time and labor costs in manufacturing operations blocks, high strength of sewing binding and good quality of mechanical processing of the spine, full use of the technological capabilities of printing machines and minimal costs in prepress processes, allows you to get the maximum strength and durability of books.

The production of simple book notebooks from prints obtained on sheet-fed printing machines includes the operations of colliding, trimming, and cutting sheets into parts, folding, pressing and binding notebooks and storing them until all structural parts of the book block are ready for further processing.

Sheet collision

Alignment of the edges of various sheet materials and prints on two adjacent ends of the foot is performed in order to increase the reliability of the feeders of printing, finishing and folding machines and the quality of products of single-knife paper-cutting machines. It is necessary in cases where the shift of sheets in a stack due to inaccurate operation of the take-up device of sheet-cutting and sheet-fed printing machines or careless transportation exceeds the tolerances for the amount of shift of sheets for the smooth operation of feeders, for the format and accuracy of cutting sheet materials and products. Unprinted paper, prints and various sheet binding materials are collided before printing, finishing, cutting and folding.

Push technology

Sheets are collided manually, on colliding semi-automatic machines and on automated integrated systems, which include a colliding machine. Pushing sheets manually is performed on a horizontal table with a flat and smooth surface, the width of which is somewhat greater than the diagonal of the sheets being processed. With manual pushing, the worker transfers a small (convenient to work) stack of sheets from the pallet to the pushing table, forms an “air lubricant” between the sheets of the stack with special techniques, spreads the stack with a “ladder”, aligns it with soft blows on the table surface alternately along the edges of the right angle, after pushing the air between the sheets with the palm of his hand and placing the stack on the feeder table, cutting machine, or other pallet. On a collided foot, the correct edges are marked with a colored pencil or, if the paper is intended for printing covers and postcards, by cutting off the right corner up to 10 mm from its top. When sealing the front side of the sheet, the right angle is marked with a special mark - a narrow strip up to 3 square meters long. on the side of the sheet. The marks in the stack form a clearly visible stripe on the end face.

With manual pushing, the labor of the worker is heavy and unproductive: he lifts and lowers each stack of paper to the surface of the table from 2 to 6 times, processing up to 4 tons of paper per shift. In small and medium-sized printing enterprises, simple-designed and affordable collating machines are used for colliding. Such a machine has a massive base, a table with two low walls-stops, a sheet blowing system and an electric drive that ensures the vibration of the table during the collision. During operation, the table occupies an inclined position, and the sheets, due to air lubrication and their own gravity, are aligned against the side walls. The loading of the pusher machine should be done in small stacks, since with a large mass of the stack, the sheet blowing efficiency is significantly reduced, and the time for aligning the sheets along the side walls increases. Modern medium and large printing companies use automated complex systems that serve the processes of pushing, cutting and all related transfer operations.

After colliding, sheets of paper and prints should be counted and stacked in stacks of 500 copies on pallets in stacks whose height should not exceed 1.6 m. Stacks should be separated from each other by strips of colored paper to assess the amount of work performed and the amount of paper available or semi-finished products.

Paper and semi-finished products after colliding are evaluated by a single quality indicator - colliding accuracy. The sheets in the stack must be exactly aligned, with a tolerance of 3 mm for paper and 4 mm for binding cloth. The accuracy of the collision is determined visually when the foot is "pumped" along the correct edges.

Factors affecting colliding accuracy and performance

The accuracy and performance of manual and machine pushing of sheets depends on the size, surface density, bulk density, smoothness and moisture content of the paper, as well as on the average value of the initial offset of the sheets and the condition of their edges.

Sheets of large format are less convenient to work with and, other things being equal, have a large mass, therefore, a stack of paper with a smaller number of sheets is taken for pushing than with medium and small format. The colliding performance is reduced by 17-20%. Paper with a high surface density, other things being equal, has a higher mass, thickness and stiffness, which has a twofold effect on the complexity of the operation: on the one hand, it is necessary to push stacks of paper with a smaller number of sheets, but, on the other hand, thick and rigid sheets of paper are relatively edges are easily aligned. For these reasons, for every 20% increase in paper basis weight, the jogging performance of paper over 90 g/m2 decreases by about 5%. Colliding sheets of thin types of paper with a low surface density is difficult due to their low rigidity. When aligning sheets on a hard surface of a table or the walls of a pushing machine, the probability of crushing their edges increases significantly. With this in mind, the production rates per collision of paper with a basis weight below 55 g/m2 are reduced by about 17%. Thin types of paper with a low surface density (for example, cigarette paper with a surface density of 16 g / m2) cannot be collided at all; they are leveled by pinning each sheet onto needles.

Sheets of calendered and coated paper with high smoothness slide well over each other and collide easily. High-calendered paper with a smoothness of more than 300 s and coated paper before trimming and cutting can not be pushed at all, but aligned by pushing it to the feeder and stop when laying the stack on the table of a single-knife paper-cutting machine.

The increased humidity of the paper makes it difficult to collide, as this reduces its rigidity and increases the coefficient of friction. At low (less than 5%) humidity, paper is easily electrified by close contact and friction of the sheets. The accumulation of charges during electrification leads to sticking of the sheets, which makes it difficult to perform basic colliding operations. The optimal moisture content of paper for this technological process, equal to 7-8%, can be achieved at normal relative humidity in the workshop (60 ± 5)% and after acclimatization of the paper for a day.

Large initial shift of sheets, wavy, wrinkled and damaged sheet edges make it difficult to collide. At the same time, when loading flat pile feeders of printing, finishing and folding machines, collisions may not be performed if the initial sheet shift does not exceed 3 mm. When loading round pile feeders of folding machines, collisions can be avoided even with a larger (up to 10 mm) offset of the edges of the sheets.

Question number 2. To characterize and describe the technology of manual picking and picking processes.

Making book blocks

The production of book blocks means two operations - the assembly of blocks and their fastening, but these are the key, most important operations in the technology of stitching and binding processes, since the quality of their execution to the highest degree determines the main consumer properties of book-type publications: ease of use and required durability.

Completing blocks with a tab (notebook in a notebook) is used in the manufacture of small-volume book publications - “thin” magazines for various reader purposes, books for children of preschool and primary school age, technological instructions for individual operations, various documents (membership cards, record books, etc. .) and white goods. The volume of such publications and products usually does not exceed 128 pages, and the block thickness is 6.5 mm. The thickness of the book block when assembling with a tab is limited because the width of the outer shares of the paper sheet after cutting the block or publishing when bending the inner shares along the radius R (Fig. 5.1) decreases by an amount l proportional to the thickness of the block:

where W - block width before trimming, mm; Tb - block thickness, mm.

In the finished product, this leads to a significant reduction in the margins on the inner sheets, since even with a snug fit in notebooks and precise folding, with a block thickness of 5-6.5 mm, the leading edges of the sheet shares and typesetting strips at the outer sheets of notebooks are shifted by 4- 5 mm, which, of course, reduces the quality level of book publications, but it is quite acceptable in the production of white goods - weeklies, general notebooks, etc.

Book block assembly technology

The picking of blocks with an insert and a selection is done manually, on insert-sewing machines, on insert-sewing-cutting units and on pick-up machines, moreover, in the manufacture of publications in a cover, picking with an insert is always combined with covering with a cover.

Manual picking with a tab

At small printing enterprises, with a shift load of the workshop for the operation of completing blocks of up to 18-20 thousand three-fold notebooks, one worker can complete the assembly with an inlay with covering the blocks with a cover. Manual picking of book blocks with a tab is carried out on a horizontal table after a preliminary check of the stacks of notebooks according to the norm and signatures by pouring them “on a fan”. The stacks of notebooks are placed on the right side of the table with the initial pages with the signature down, the top edges towards themselves and the spines to the left (Fig. 5.2).

Rice. 5.2. The layout of notebooks and blocks for manual assembly of blocks with an inlay: B - a stack of internal notebooks; H - foot of outer notebooks; O - stack of covers; B - stack of completed blocks

The stack of inner notebooks is placed first on the right, and the stack of outer notebooks is placed last on the left. To the left of the stack of outer notebooks, a stack of covers is placed. For the convenience of work, the stacks of notebooks and covers are made of different heights so that each foot on the left is 1-1.5 cm lower than the right. The height of the right foot should not exceed 20 cm, otherwise it may crumble with careless movement. A stack of folded covers is laid in expanded form with the folds upwards and the upper edges towards themselves, since in the folded form it is impossible to lay the covers in a relatively high stack and it is difficult to separate them one by one during the folding process.

When working, the stitcher with his right hand separates the upper notebook of the extreme right foot and at the same time with his left hand opens the upper notebook of the adjacent foot located on the left, after which he pushes the inner notebook of the block into the outer one. Then the movements of the hands are repeated: with the right hand, part of the completed block is pushed into the next notebook of the third foot opened with the left hand, etc., and the entire block is pushed into the cover opened by the left hand. The completed and covered block is placed on the left edge of the table. When the height of the stack of completed blocks reaches a value convenient for further processing, it is carefully pushed first along the upper edge, and then on the spine and placed on the adjacent working table of the wire sewing machine or in trucks to be sent to subsequent operations or to the warehouse of semi-finished products.

In the manufacture of publications in the binding cover, the technology for completing blocks with an inlay is similar, but the process of completing the assembly itself ends with inserting parts of the blocks into outer notebooks with endpapers glued on both sides and edged spines.

Manual picking

Manual picking of book blocks with a selection with a small number of notebooks in blocks, as in the case of picking with an inlay, is performed on a horizontal table. Before laying on the table, the worker controls the quality of incoming semi-finished products, rejecting soiled and damaged notebooks; on the spines or on the upper edges of the stack of the last notebooks of the block, a mark is necessarily applied with a colored pencil to facilitate the separation of the completed blocks before they are fastened together. This mark can also be the mark of the performer, if two or more workers perform the picking.

If there are no more than 8 notebooks in the block, then the stacks of notebooks are placed on the table in pairs, at an equal distance from the performer's workplace, with the spine folds to the right and the upper edges towards themselves, in the order indicated in Fig. 5.3. The assembly of blocks begins with the last notebook, laying it with your right hand on the table in front of you, after which the penultimate notebook is placed on it with your left hand. Further, the picking process is repeated until the stack of assembled blocks reaches a height convenient for further processing.

Rice. 5.3. Scheme of laying stacks of notebooks when completing with a selection of small blocks: 1-8 - stacks of notebooks; B - stack of completed blocks

If the number of notebooks in the publications is more than 8, then a stand 10 cm high is installed on the desktop so that the stacks of notebooks can be stacked in two rows at different heights. In the first row, farthest from the worker, stacks of notebooks of the first half of the block are placed on a stand, placing them from left to right. In the second, near, row, stacks of notebooks of the second half of the block are laid from right to left. The assembly of blocks begins with the last notebook, placing them on the palm of the left hand or on a cardboard blank of the appropriate format and moving along the table from left to right and right to left. At one time, the worker picks up several blocks with a foot of such a height that is convenient for him to work.

If the number of notebooks in book publications is more than 20, then it is advisable to make the desktop U-shaped. In this case, the worker can perform picking while sitting on a screw chair. At

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Throughout life, a person is accompanied by notebooks. From childhood to old age, in any situation, they are present in human activities. By design, a notebook is very similar to a book. Paper can be clean, lined, checkered, contain margins, logos, and various information.

Mounting method

Manufactured notebooks to order can be fastened in a variety of ways: on glue, on a thread, on a spring, on a special wire, fastening with the possibility of replacing sheets.

Bonding with glue or milling is the most commonly used method. It uses special synthetic polymers that form elastic dense coatings after cooling.

In the manufacture of notebooks with a small number of sheets, nylon or cotton threads are used to stitch the spine.

For non-standard sizes, the method of winding on a spring can be used. Notebook on a spring- a fairly common option. If it is necessary to replace pages, there are special devices with drop-down mechanisms.

Formats

In a modern office, large format notebooks are most convenient to use. The company "Vse polygrafiya" brings to your attention promotional notebooks A4 format. Such products are printed blocks of A4 format of various sizes with logos and various advertising information on the covers and pages. These notebooks are used for draft notes, working notes, for notes at conferences and meetings, during various presentations, for shorthand.

You can use notebooks for educational purposes, and at home for various notes and reminders, in business and advertising purposes. They can be made in various sizes (notebook 96 sheets, 80, 100 or 160).

Materials and manufacturing methods

The general notebook is produced in several sizes established by GOST - 48 pages, 60 pages, 96 and 120 pages. The following types of paper are used as a material for the production of block pages: plain writing, offset, newsprint, coated paper. The covers of common notebooks are made of chrome, coated, bookbinding or recycled cardboard, chrome-ersatz, cardboard with polymer or starch-kaolin coatings, bumvinyl of different colors.

Currently, in the segment of bound books, as well as in most other segments of the printed matter market, there is a clear trend towards a decrease in circulation. To fulfill such orders, automatic stitching lines, which have been left at some enterprises since Soviet times, are ineffective, and therefore it can be stated that a rather attractive new market niche is gradually emerging - the production of small editions of bound books on semi-automatic equipment.

The production of high-quality bound books can definitely be called one of the highest levels of printing skills. A distinctive feature of the production process of this type of product is the complex post-press processing, which includes three main stages:

  • production of a book block;
  • cover making;
  • assembly and finishing of the book.

Making book blocks

For the manufacture of book blocks, notebooks are formed from printed sheets, which are then selected into sets, fastened together by sewing or seamless.

Making notebooks

Notebooks are divided into simple and compound. The first ones are a folded printed sheet, the second ones include additional elements: adhesives and/or pastings.

Folding

The folding operation serves to form notebooks of the required format and design from printed sheets (canvas).

The number of folds performed when folding book publications usually does not exceed four, which makes it possible to obtain 32-page notebooks, however, growing in last years the use of sheet and roll machines of very large format led to the introduction of 48 and 64 page notebooks with five folds. The number of folds may be limited depending on the thickness and weight of the paper. Thick rigid papers are folded with fewer folds than thin papers (if it is impossible to obtain a notebook of the required format by folding, the stack is cut). Coated papers are usually folded in no more than three folds (16-page notebooks).

The folding scheme depends on the ratio of the format of printed sheets and the format of the book, as well as on the requirements for the design of notebooks. According to the relative position of the folds, there are parallel (each subsequent fold is parallel to the previous one), perpendicular (each subsequent fold is perpendicular to the previous one) and combined folding. According to the location of the folds on the sheet, folding is divided into symmetrical and offset. In book production, when receiving 8, 16, 32 and 64-page notebooks on operating equipment, as a rule, symmetrical perpendicular folding is used, and in the manufacture of 12, 24 and 48-page notebooks, a combined one is used.

Preferably, in notebooks formed as a result of folding, the machine direction of the paper is parallel to the spine. With such an arrangement of fibers, the folds have a clear shape with minimal deformation loads on the paper, which improves the opening of the book and contributes to a greater bonding strength of the block. It is also recommended that the head of the notebook be closed, since such notebooks are more technologically advanced for further processing (especially in the case of using opener feeders).

Folding can be done in the folding cutter modules of web presses or on the operating equipment that is used to process prints made on sheetfed presses. On roll-to-roll printing machines, as a rule, large-circulation products are produced, therefore, the main equipment for folding medium and small runs are automatic operating machines.

Regardless of the technological characteristics, automatic folding machines include the following main modules: feeder, folding sections, receiving device. The sheet transport system is used to transport the sheets through the sections of the machine. In addition, folding machines can be equipped with additional technological units and modules.

In modern folding machines, two types of feeders are used: flat pile and round pile. Flat pile feeders feed sheets from a vertical stack installed on a flat table, and round pile feeders include two tables: sheets are stacked on the upper table with a slight shift relative to each other (inlet), forming a cascade flow, and the lower table serves to feed sheets into the machine. The main advantage of round pile feeders is the ability to load paper without stopping the machine, however, they have large dimensions and relatively small capacity.

Sheets are fed through the folding machine by roller or ribbon conveyors. Ribbon conveyors are less expensive than roller conveyors, but roller conveyors provide more stable sheet transport conditions.

The folding of the sheet is carried out by a pair of steel rollers, which compress the bent sheet - the so-called loop, forming a fold. The crimping force is determined by the distance between the folding rollers and depends on the thickness of the paper, the number and relative position of the folds and the orientation of the fibers in the sheet. More force is required when folding thick paper, multifold notebooks, and when forming folds across the grain of the paper.

Depending on the method of forming the loop, folders are divided into two types: cassette and knife. Cassette folding apparatus includes a system of three rollers and a cassette. The rollers are designed to feed the sheet into the cassette, form a loop and fold the sheet. They form two pairs: feeding and folding (one roller is common). The cassette has a cavity for the entry of a sheet with a limit stop and is installed at an angle to the horizontal plane.

The cassette section can contain several staggered cassettes that can be used to form parallel folds, including wind and accordion folds.

In knife folding machines, the loop is formed as a result of deformation of the sheet with a knife. The depth of the knife lowering is selected so that it reliably inserts the loop between the rollers, but does not touch their surface.

The main advantage of knife folding machines is the high accuracy of folding when working with materials of various thicknesses, including a large number of folds. Knife folders are compact, but their Maintenance and manual adjustment are difficult due to poor accessibility of mechanisms. The significant disadvantages of knife folders include a limited choice of folding schemes (parallel folding is usually impossible) and limited productivity due to the presence of a reciprocating knife in the mechanism.

Cassette folding units offer a very wide range of folding patterns and are highly productive because all of their mechanisms either rotate with constant speed or immobile. They are relatively simple in design and easy to set up. However, the accuracy of the cassette fold is lower than that of the knife fold and is highly dependent on the thickness of the sheet. Folding very thin and very thick papers in cassette devices, as well as obtaining multi-page notebooks, is usually technologically difficult or impossible.

At present, combined folding machines are widely used, in which the first folds are formed in cassette sections, and the last - in knife sections.

Folding machines can additionally be equipped with punching devices for cutting, creasing and perforating sheets, glue devices, as well as a sewing device with thermal thread (see below). Cutting with a circular knife can be used in the manufacture of notebooks and makes it possible to increase the utilization rate of the machine format. Creasing and perforation are used to facilitate the formation of a fold when working with dense materials or with a large number of folds.

The receivers of the folding machines form a cascade stream or a horizontal stack of folded notebooks.

gluing

Composite notebooks are a folded printed sheet, complete with additional elements: endpaper, illustrative inserts, inserts with geographical maps, etc. Additional elements are glued to the notebook from the outside or glued inside.

Endpaper - a paper or combined part that connects and fastens a book block with a binding cover. The endpaper is glued either to the first and last notebooks of the block before the selection, or to the selected and fastened block.

According to the design and method of attachment to the block, there are about ten types of endpapers, however, in practice, in the vast majority of cases, a simple adhesive endpaper is used, which, with a large volume of the book, can be edged with paper or cloth.

The endpaper is made of special paper, strong on a break. When using dispersion cold glue, waterproof paper should be used. The mass of endpaper paper should be the greater, the larger the volume of the block and the mass of paper of the block. The endpaper cut must be fractional so that the fold is made in the machine direction.

The position of gluing a simple endpaper to a notebook depends on the method of fastening the block. With sewing binding, the endpaper is glued 12 mm from the spine, with seamless binding with cutting of spine folds - at least 5 mm from the spine, when binding notebooks with thermal threads - without indentation. The width of the adhesive strip should be 45 mm.

The edging of a simple adhesive endpaper can be done using a narrow paper or fabric tape in the case of a block sewing fastening. Paper tape edging is recommended in cases where the volume of the block exceeds 400 pages, fabric tape - when the volume of the block is more than 640 pages.

Gluing additional elements inside the notebook is usually done manually; semi-automatic and automatic equipment can be used for gluing. There are machines for gluing endpapers (or other elements) to notebooks and machines for gluing endpapers to blocks.

Automatic notebook gluing machines include a notebook feeder, endpaper (or other) feeder, conveyor, glue machine, crimping device and receiving device. Glue is applied to the notebook or endpaper - depending on which of these elements is served first. After aligning the booklet and endpaper, which are at different levels of the conveyor, they are fed into the roll or belt crimping section, where gluing is performed. After gluing additional elements, the adhesive must be dried.

Automatic machines for gluing endpapers to the block have a similar principle of operation - with the difference that two endpapers are glued simultaneously, which requires two endpaper feeders, two glue machines, and the conveyor must have three levels. Such machines, as a rule, are aggregated with other equipment for processing blocks, and therefore do not have their own block feeder and receiving device.

Sticking endpapers to blocks compared to sticking to notebooks has two main advantages: the ability to accurately position the endpaper at the spine, which maximizes bonding strength, and high bonding performance, since both endpapers are attached at the same time. The disadvantage is the impossibility of edging the flyleaf.

Selection (block assembly)

Book blocks are completed with a selection: notebooks are superimposed one on another in a given sequence. This method of assembly, unlike the tab, does not impose restrictions on the volume of the block.

Automatic selection of notebooks is carried out in collating machines, the main elements of which are feeders, a conveyor and an output device. Modern collating machines are built according to a linear horizontal scheme: notebooks are sequentially fed to the conveyor table from feeders installed on the same horizontal line. Currently, feeders are mainly used with the output of notebooks from the bottom of the foot, since such a scheme makes it possible to replenish the stock of notebooks during operation without stopping the machine.

Each feeder contains notebooks of a certain signature. Notebooks are loaded into feeder magazines in sequence from the receiving device: in last shop- the first notebook, in the penultimate - the second, etc. The last notebook is fed to the conveyor first, then the penultimate one is placed on it, and so on until the block is complete. In case the collating machine does not contain a sufficient number of feeders, manual feeding of partially pre-selected sets into the machine can be provided.

Compiling machines can be aggregated with equipment for fastening blocks, in particular with machines for adhesive seamless bonding.

Block fastening

The main ways of fastening book blocks are sewing with threads and adhesive seamless binding. In addition, interesting, although not widely used, is the technology of binding notebooks with thermal threads with further adhesive bonding of the block.

Sewing blocks with threads

Sewing with threads is the oldest technology for binding book blocks, which was used in the Middle Ages in the manufacture of handwritten books. Its long existence is due to the fact that sewing with threads provides the greatest strength and durability of the block fastening.

A distinction is made between block and tetrad sewing, however, in Russia, only tetrad sewing is traditionally used. Its advantages include high block bonding strength and good opening of the book. In addition, single stitch sewing does not impose restrictions on subsequent block processing operations. The main disadvantages of this binding method are high labor intensity and the dependence of sewing productivity on the volume of the block: for blocks containing a different number of notebooks, the binding time is different. This feature of potterydny sewing significantly complicates the aggregation of sewing equipment with picking machines and lines for in-line processing of blocks.

Thread sewing machines for notebook sewing are divided into automatic and semi-automatic machines. Sewing machines are equipped with self-feeders, openers of loop and loopless (flipping) type notebooks, and in semi-automatic machines, the notebook is opened and placed on the machine table manually. The correctness of the number (signature) of the notebook can be automatically controlled using a photo sensor.

Notebooks in the process of sewing are connected by several continuous threads that form seams. Each thread is folded in half, drawn into the notebook through one hole and pulled out through the other. The loops form a chain, and the last loop in the seam is tied with a knot.

There are four types of stitches used in block stitching: simple booklet, simple bookbinding, folding booklet and folding bookbinding. In bookbinding sewing, the binding material is sewn to the block. Depending on the number of types of supported stitches, sewing machines are divided into universal and specialized.

The formation of stitches occurs as a result of the interaction of sewing tools: punctures, needles, hooks and gates. The punctures form holes in the fold of the notebook opened in the middle, the needles lead the threads into the holes, the gates pass the threads to the hooks, which bring them out. The stitched notebook is pushed onto the receiving table of the machine - to the rest of the notebooks of the block. After stitching a complete set of notebooks to tighten the knots and separate the blocks from each other, an idle stitch is performed, and then the thread between the blocks is cut. For additional strengthening of the block, the outermost notebooks can be glued along the spine (glue is applied before sewing).

It should be noted that the greatest strength of sewing binding is achieved when binding notebooks with at least 16 pages, and it is strongly recommended that all notebooks have the same volume.

Since automatic sewing machines are quite expensive, for most printers who decide to equip their post-printing area with sewing equipment, a semi-automatic machine will be the best choice.

Adhesive seamless bonding

With adhesive seamless bonding (CBS), the sheets in the block are fastened with an adhesive film. Compared to sewing with threads, KBS has the following advantages:

  • high speed;
  • independence of the performance of the bonding process from the volume of the block, which makes it easy to aggregate machines for BBS with picking and block processing equipment;
  • relative simplicity and low cost of equipment.

At the same time, adhesive-bonded blocks have lower strength and worse openability than those sewn with threads. Another significant disadvantage of KBS is the unsuitability of this method for bonding hard, poorly absorbing glue papers (for example, coated papers).

It is customary to distinguish three types of CBS:

  • without cutting back folds;
  • with partial cutting of spine folds;
  • with full cutting of spine folds.

The idea of ​​KBS without cutting back folds is very attractive, since it allows you to achieve quite significant paper savings with good opening of the book and the absence of damage to the spines of notebooks with sewing tools. The main problem of KBS without cutting back folds is the fastening of sheets inside the notebook. To solve it, stitching sheets with thermal threads (see below) or gluing sheets can be used. Gluing can be performed both in the folding process and in the KBS machine by activating the pre-applied hot melt adhesive. Another option for implementing the CBS without cutting the spine folds is the use of "accordion" folding, in which notebooks do not have sheets nested into each other. However, it is extremely difficult to achieve high accuracy of alignment of the root folds with such folding. Currently, CBS without cutting the spine folds is used relatively rarely.

KBS with a partial cut of the spine folds involves the removal of 60-80% of the spine folds by perforating the spine folds, forming slots or milling the middle part of the spine to a depth of 1.5 mm. Removing the folds allows the glue to penetrate to the inside of the notebooks, while the remnants of the folds help the pairs of sheets to be firmly held together. At the same time, KBS with a partial cut of the spine folds is not recommended for notebooks containing more than 16 pages, since in this case the opening of the book may deteriorate and a strong adhesion is not achieved. inner sheets notebooks.

Seam punching can be done in folding machines, but slotting and milling require specialized equipment. To increase the bonding strength of the blocks, reinforcement of the milled part of the spine with woven or non-woven synthetic materials can be used.

The most widely used in book production is the CBS technology with full cutting of spine folds. With this technology, the block is divided into separate sheets, followed by their connection with an adhesive film. The KBS process with full cutting of spine folds includes the following operations:

  • mechanical removal of spine folds;
  • torshonirovanie - giving the surface of the spine roughness;
  • removal of paper dust;
  • applying glue;
  • glue drying.

Removal of spine folds is carried out with the help of special cutting tools - end mills or circular knives. The minimum required cut depth is equal to the thickness of the spine of the notebook, that is, the greater the greater its page size and paper thickness.

In the first case, the waste has a dusty appearance, and the cut has a strong roughness, in the second, the waste is paper chips, and the cut is characterized by high smoothness. Cutters and circular knives can be monolithic with soldered teeth or composite with removable cutters.

To remove the folds, the block is moved by special disks or gripper strips relative to the rotating cutting tool. The plane of rotation of the tool is slightly inclined relative to the plane of the spine, so the teeth of the cutter or knife do not touch the already machined part of the block.

After removing the spine folds, the surface of the spine of the block can be subjected to additional processing in order to improve the contact between sheets and glue. The quality of the spine after milling is determined by the strength of the paper, the geometry of the cutting tool, the degree of its sharpening, the depth of cut, the feed rate of the block, and many other factors. Ideally, the spine surface should be rough with a macro-roughness height of up to 0.4 mm, which maximizes the area of ​​contact between paper and glue while maintaining the strength of the sheets - without the formation of tears. To form such a surface, torshoning is used with the help of end tools: brushes, emery discs, etc. Torchonirovanie must necessarily be performed in the case of cutting folds with circular knives (when using end mills, the roots may have a roughness sufficient for strong gluing). Additional processing the spine after cutting the folds also includes the application of transverse grooves up to 1.5 mm deep in increments of 2 to 20 mm. The grooving cutters can be attached to the torsion head.

In high-performance KBS machines, fold cutting and toning are usually performed in separate sections; in low-speed machines, these sections can be combined.

After torshoning, the spine is cleaned of paper dust with the help of end or cylindrical brushes.

Currently, cold dispersion adhesive based on PVA and hot melt adhesives of various compositions are used for KBS. Cold glue PVAD is characterized by good penetration, good adhesion to a wide range of papers, high elasticity of the adhesive film, as well as the constancy of its properties over time. The main disadvantage of PVAD is the need for intensive drying, which requires high energy consumption.

Hot-melt adhesives are characterized by a high fixing speed, however, they were inferior to PVAD for a long time in terms of elasticity, adhesive ability and resistance to aging of the adhesive film. The situation has been changed by the development of polyurethane-based hot melt adhesives (see article "Polyurethane hot melt adhesives for seamless bonding" in CompuArt No. 4'2007), which, in terms of their characteristics, are not only not inferior, but even superior to PVAD. At present, many Western printing houses have already accumulated successful experience in the use of adhesives of this type.

The designs of adhesive devices in modern KBS machines are very diverse. As a rule, these devices have an individual drive, which ensures the equality of the circumferential speed of rotation of the application rollers and the linear speed of the block. Squeegees are used to control the thickness of the adhesive applied. The glue apparatus may contain additional rollers or brushes for rubbing and smoothing the glue. Excess glue is removed with a special scraper. Apparatus for applying hot melt adhesives are equipped with temperature control systems. Sometimes, especially when using polyurethane hot melt adhesives, such devices may have a closed design.

In some KBS machines, cold glue is applied in two stages: in the first glue section, a thin layer of liquid composition is applied, which is well absorbed and penetrates deeply into the paper, and in the second, a thick layer of more viscous glue is applied.

For drying cold glue, infrared radiation or microwave currents are used. Hot-melt adhesive is fixed during cooling and, as a rule, does not need forced drying.

An additional operation after gluing the block can be its edging with paper or fabric tape in the corresponding section of the KBS machine. To do this, a special glue machine performs lateral lubrication of the block or edging tape. In practice, both longitudinal and transverse supply of edging material is used, which is cut off from the roll, positioned on the spine and pressed against it.

The transport system of the CBS machines can be built according to rectilinear, circular (carousel) and closed rectilinear circular schemes. According to the first scheme, mainly low-performance machines are built, according to the second - machines average performance, on the third - high-performance systems.

Sewing with thermal threads (sewing and adhesive bonding)

Sewing with thermal threads is a technology that allows you to firmly fasten sheets in notebooks. For sewing, a special thread is used, which includes a component that melts when heated. At the place of the future fold, notebooks are stitched with several thread
U-shaped staples, the ends of which are welded with a heated bar to the paper. After that, the last fold of the notebook is formed on the folding funnel. The selected sets of notebooks sewn with thermal threads are glued together in a block (the folds are not removed).

The main advantages of sewing with thermal threads:

  • high bonding strength, comparable to traditional thread sewing;
  • good disclosure of books;
  • high sewing speed, which allows aggregating equipment for fastening with thermal threads with folding machines.

Unfortunately, equipment for sewing with thermal threads is quite expensive and is produced by only one company - the manufacturer of printing machines.

Block processing

The process of processing bonded blocks may include the following operations:

  • block crimping;
  • gluing and drying of the spine;
  • spine crimp;
  • three-sided cutting of the block;
  • trimming;
  • spine rounding;
  • bending folds or edges;
  • gluing of root material;
  • gluing a ribbon bookmark;
  • gluing captals;
  • gluing a paper strip.

Mandatory operations for blocks fastened with threads are gluing, drying and crimping the spine, as well as three-sided trimming, while the rest of the operations are performed if the relevant requirements for the design and durability of the book are presented. For glued blocks, only three-sided trimming is required.

The crimping of blocks fastened by sewing before gluing the spine is performed in order to calibrate them in thickness. In addition, during the crimping process, the holes made in the folds by sewing tools are compressed, which prevents the penetration of glue through them into the block. To achieve better compaction of blocks in block processing units, crimping is performed repeatedly. After crimping, the spine is sealed, as a result of which the spines of the notebooks are additionally fastened with an adhesive film, which gives the spine of the block solidity and strength.

When cutting blocks on three sides, all folds are cut off, except for the root ones, and the block acquires its final geometric dimensions. Trimming is performed in one step with a three-blade cutter or in three steps with a single-blade cutter. In the second case, the lower edge of the block is cut first, then the head, and only after that the front edge. When cutting the bottom and top edges, the block should be laid so that the knife first cuts into the spine, as this minimizes the risk of tearing out part of the spine.

Shading trims - an operation that improves the appearance of the book - is performed on automatic machines or manually. There is also automatic and semi-automatic equipment for metallization (as a rule, gilding) of cuttings with printing foil. In such machines, the cut surface is pre-sanded and coated with a primer varnish.

Rounding the spine - giving the spine of the book block and its front edge a rounded shape - is performed to align the block in thickness and improve the opening of the book. In semi-automatic machines, rounding is performed by pushing into a profile block; in automatic block processing lines, rolling in rollers is often used.

Folding the folds (edges) of the spine of the block - giving the spine a mushroom shape - helps to increase the strength of the block and the strength of the fastening of the block to the binding cover, since the folded folds create support for the sides of the cover. Folding of folds is usually carried out using a profile block or a profile roller.

Gluing the bookmark ribbon, spine material, captals, and paper strip to the spine completes the processing of the block before inserting it into the cover. The spine material and the paper strip serve to reinforce the block.
If the block was fastened with threads with sewing on of printing gauze (binding stitches), gluing an additional strip of spine material may not be performed.

Kaptal - cotton, semi-silk or silk ribbon up to 10 mm wide with a thickened edge. The captal is glued to the upper and lower edges of the block in order to additionally fasten them and cover the gap between the spine of the block and the spine of the cover.

Block processing can be done manually, on operating equipment or on automatic block processing lines. In the conditions of small-scale production, the use of semi-automatic equipment in combination with manual labor in performing some rare operations (for example, if it is necessary to glue the bookmark) seems to be a rational choice.

Ending in the next issue

School notebooks and notebooks are always needed - this is the main argument in favor of starting a business. Start-up costs may seem high, but the investment will pay off if you establish sales. This business is for those who are ready to organize an enterprise.

The idea of ​​producing school notebooks and stationery is not new, but always successful (see ""). Most entrepreneurs who decide to start a new business prefer to sell.

Production, according to many, requires much big investments time, effort and resources.

It’s hard to disagree with this, but you can’t help but take into account that by producing something, you drastically reduce the number of competitors and increase the profitability of your business. In addition, there are categories of products that do not require too much investment in production, and at the same time are constantly in demand. The production of school notebooks is a classic example of such a business.

Challenges of the notebook business

Speaking about the production of school notebooks, we need to make a few clarifications. The cost price of notebooks is really low, and the retail margin is small.

Investments will be needed in the organization of sales and they will amount to 40% of the cost. Small enterprises cannot increase production enough to compensate for these losses, so in order to increase profits they have to release other products along the way, which can be charged a higher markup. Such goods include notebooks, envelopes, diaries, note paper, etc.

Still, the interest in this segment is quite understandable. Another product that is equally convenient in the production and sale of goods is difficult to find. School notebooks are changed, as a rule, several times a year, and there are no special requirements for them.

Buyers choose notebooks based on their price, appearance and paper quality. Paper in notebooks for primary school students should be perfectly white, thick and smooth.

Although notebooks do not last long, manufacturers should try to make them durable, because sometimes the notes in notebooks must be stored for several years. The standards that manufacturers must adhere to when making the inner block of a notebook: clear margins, even rulers, density 65-80 g / sq. m, whiteness 92-95%.

Main consumers

The target audience is schoolchildren from 6 to 18 years old, so the demand for notebooks largely depends on the demographic situation. Since the beginning of the century, there has been an increase in the birth rate in the country, which means that the target audience is also increasing.

When determining the range of notebooks, it is important to choose the right cover design. For elementary school students, covers with pictures of animals or cartoon characters, cars or robots will be good.

The picture should be bright and colorful. On the other hand, in some schools, teachers require notebooks to have plain covers. This should be taken into account when forming an assortment of thin notebooks of 12–18 sheets. For middle and high school students, notebooks with photographs of popular movie characters or musical performers are suitable. The older the children, the more discreetly designed notebooks they choose. Students already prefer business-style design.

Notebooks are not super profitable goods. First of all, this applies to notebooks up to 48 sheets with a one-color cover, the most budget option. At the same time, the production of common notebooks with colorful covers is considered profitable. The main buyers of these products are middle-income people who do not buy common notebooks so often, so they are ready to pay more for them.

Production of notebooks

Simple book notebooks are printed from prints on sheet-fed printing machines. The production process consists of several stages:

  • collision,
  • pruning,
  • sheet cutting,
  • folding,
  • pressing,
  • notebook bindings,
  • warehousing.

The raw material for production comes in the form of pressed pulp, which is mixed with water and chemicals. After that, the mixture enters a special unit that processes the mass into paper. The resulting paper is lined and cut into separate sheets.

Sheets are pushed together manually, on semi-automatic machines and on automated lines. Manual pushing is too heavy and expensive, so it is practically not used. At small printing enterprises, simple and inexpensive collating machines are used.

These machines have a massive base, a table with two low walls-supports, a sheet blowing system and an electric drive that provides table vibration. On the modern enterprises work automated systems, performing the whole complex of operations - from colliding to cutting. Notebooks can be sewn together in different ways: with metal staples, threads or glue.

Costs and payback

Production requires the following equipment:

  • crimping press,
  • wire sewing machines,
  • sheet cutting machines,
  • three-knife paper cutting machines (at least two),
  • punching machine (or punching and creasing machine),
  • folding machine,
  • foil stamping equipment,
  • printing machines.

Some machines may not be new, but in working order. This will save half the amount. However, many machines offered for sale by printing companies are obsolete and worn out. It is also necessary to take into account the harmful printing production therefore, all equipment must have environmental safety certifications.

New equipment can be ordered at domestic machine-building enterprises or buy abroad. The cost of equipment is approximately 5 million rubles.

The following premises are required for the installation of equipment:

  • workshop with an area of ​​at least 1,000 sq. m,
  • administrative premises and warehouses for raw materials and finished products.

The enterprise will need 75-80 workers to operate.

To open a printing company of average productivity, you need an investment of at least 10,000,000 rubles. The payback period of investments is over 3 years.