It all started innocently enough. My plan was to do a short video about using alternative folding machine setups to crease and fold paper that is prone to fiber cracking. I had a few problem jobs on hand that I knew would be perfect subjects. It would be fast and simple. Crease and fold a handful of sheets conventionally, using fold plate #1, to illustrate how they cracked. Then run those sheets in fold plate #4 to show how you can eliminate the cracking.
One of the frequently asked bindery questions we get here is, “Don’t I need a special attachment like a Rotocrease to crease or perforate on my folding machine?” The short, simplified answer is, “No.” Based on the experiences of thousands of our customers, the majority of print finishing departments can successfully crease and fold cover stocks on their floor-model folding machines.
This week we have a bindery video for you about how to produce some very high quality perforations on your folding or scoring machine. Most experienced bindery operators and supervisors, when they first hear this, don’t really believe us. We can see it in their eyes…it’s like they’re indulging the whims of some kind but crazy distant family member.
Bindery department managers often find themselves caught in a no-man’s land where responsibility is high but authority is low. A heavy workflow with tight deadlines is the norm. But their hands might be tied with regard to authorizing overtime, hiring extra or temporary personnel, outsourcing decisions, or equipment purchases. How are managers to remain effective without giving in to frustration?
Have you ever tried to explain how a folding machine actually folds paper to someone with no knowledge of bindery equipment? Perhaps you’ve tried explaining how a saddle-stitched book is made. It’s one thing to absorb enough knowledge so that we can do our jobs. We know how to learn for ourselves. It’s quite another thing to teach what we’ve learned to someone else.
Have you ever made a purchase and immediately wished you had gone for a bigger or faster version with more features? It’s a universally recurring theme. We just upgraded to a new phone system and within one day we were asking ourselves why we didn’t get or weren’t offered a phone with slightly more capabilities. With bindery equipment purchases, this behavior usually is a result of underestimating either the actual volume of work or the time and effort required to complete it.
One of the many frequently asked bindery questions I get is, “What kind of score should I use on a 16 page right angle signature?” It’s a popular format which folds once in the main section, once in the 8pp right angle, then once in the final 16pp right angle. (see diagram at right)
My answer, which surprises many, is, “None.” You don’t need a score in there at all. In fact, adding a score to a 16 page signature can make you work harder than you should. I’ll give you the nuts and bolts answer here, and you can see it in more detailed action as we fold a 16 page signature in the video below.
One of the best and most expensive lessons I ever learned was taught to me by an unprofitable saddle stitching job. I was reminded of it, and of the unchanging nature of humans, as I read a short article in a printing trade publication. It was written exactly one hundred years ago in 1914 yet it’s still timely. First the article, and then the story of a good idea gone bad.
A Bindery Success™ reader recently sent us a story that illustrates the sometimes amusing difficulties of troubleshooting bindery work. In this case they were saddle-stitching a book with a reply envelope inserted between the pages. Stitcher operators know it’s a bit of a tricky job. It’s a delicate operation getting the envelopes to feed accurately, to remain in position, and to remain in the book so as not to cause rejects. Yet once the feeder is set correctly it tends to run all day without problems.
Fold plate indicators don’t always tell us the truth. Set one at any given length and then fold a sheet. You might get the dimension you want on the first sheet if you’re experienced on that folder. More likely you’ll have to adjust it once or twice.