Khromatec fits CABS 4000 in second UK First

Two years after installing the UK’s first automated Horizon B1 combination folding system, a Lincolnshire trade finisher has added the UK’s first CABS4000 computer aided perfect binding line, also from Graphic Arts Equipment.

“The Horizon CABS4000 gives us the next step to boost our bindery with an increase in production of at least 25,000 to 30,000 books on a single shift," states Antony Boyes, Managing Director of Khromatec.

“It provides us with the very latest in technology, speed of set-up and ease of use, coupled with the confidence in the reliability and workmanship from Horizon. In today’s environment our customers require faster turnround times with shorter lead times whilst maintaining the highest quality of finished product. The Horizon CABS caters for these criteria. As a medium speed binder it delivers where it matters most... with many short runs from 1,000 up to 50,000 copies the set-up times are supremely quick and the quality safeguards second-to-none.

“With the configuration we have selected, we have optical cameras on each gathering station to ensure the correct signature is always selected and is always the correct way round. A check weighing facility also ensures that any book that is not absolutely perfect prior to the cover being applied is rejected – yet without stopping the machine. Production is therefore maintained with the guarantee of a perfect finished product.”

The installation of the nine-clamp high speed in-line binding system that runs at 4,000 books per hour, follows the addition of the UK’s first B1 format Horizon automated folding system with continuous round feeder in September 2005.

Antony says of the Horizon AFC-744: “We are impressed by the build quality and engineering, and the consistency of the work it produces- plus it’s fast! It’s ideal for quick turnround work... most of our folding is SRA2 down to A5 which accounts for around 1.6 million sheets per month.”

He continues: “Just about every function on the AFC-744 is controlled by the touch screen interface, and every aspect of the make-ready is automated, including all the plates and side lays, which wasn’t true of the others we looked at. This means the set-up time is reduced to around five minutes, compared to over half an hour. We can also store job data for repeat work - we produce a lot of periodicals so this function is very helpful.”

Khromatec has grown from a high street copy business which was started by Antony’s father Peter in Hull 23 years ago to become a trade finisher, now based in Stallingborough, with a wide variety of equipment and a reputation for versatility: “We specialise in perfect, wire and burst binding,” says Antony, “but we take on just about every kind of trade finishing job from customers from as far away as Scotland, though mainly in the local region. As trade finishers we rarely have any control over the type of stock we are asked to process. It is therefore very important to use machines that will give us maximum continuity of operation despite what is thrown at them to maintain the highest quality of finished product.”

Antony explains that his capital investment programme is an essential factor in his drive to grow Khromatec by 30% year on year: “We want to invest in the latest equipment to keep competitive and achieve growth. We have been impressed by GAE and Horizon and we think there is great potential for JDF via the Horizon i2i system. We believe a combination folder gives us the ultimate efficiency. As a signature becomes thicker the need for greater precision becomes paramount. Even if you pre-score, a knife will give that extra bit of accuracy and ensure that each signature is the same as the previous one time after time. The Horizon is really here to handle the quick turnaround work which is always in demand.”

He concludes: “The GAE installation engineers worked fast, efficiently and were extremely tidy. Taking just two weeks to install, train my staff and begin full production.”