Stephen Austin has increased efficiency, capacity, and reliability following investment in a Horizon iCE StitchLiner Mark V next generation saddle-stitching system from IFS.

Established in 1768 as a publishing business, for the past 70 years the Hertford operation has specialised in providing world-class security printing, packaging and distribution services. It holds a royal warrant from the King and produces and distributes more than 100 million assessments to over 160 countries every year. It delivers the highest standards of security, quality and accuracy to protect the integrity and credibility of examinations for worldwide awarding organisations, governments and Ministries of Education.

To improve automation and enable it to continue to meet, and exceed, customer expectations the operation invested in two Canon presses earlier in the year – a VarioPrint iX3200 and a ColorStream 8160. The Horizon iCE StitchLiner Mark V was then chosen to support their production.

Explains Operations Director Kevin Strachan: “We identified the need to invest in new equipment to increase efficiency, capacity, and reliability across our operations. The existing machinery was reaching the end of its optimal lifecycle, and we wanted to ensure we remained competitive, sustainable, and able to meet growing customer demand.”

He became aware of the Horizon iCE StitchLiner Mark V through a combination of industry research, attending trade shows, and discussions with Canon.  “We assessed several systems from other leading suppliers to ensure we made a well-informed decision,” he expands. “Ultimately, this solution stood out due to its proven track record, local service availability, and alignment with our long-term business strategy. It best met our technical, operational, and performance requirements. We were impressed with the automatic stitch detection, and the speed that this machine could process booklets from a reel. It offered the right combination of advanced technology, ease of integration, and strong after-sales support.

“We were particularly impressed by its reliability, energy efficiency, and the level of automation it offers. It’s designed to deliver consistent output, reduce downtime, and improve product quality – all key factors for us. The supplier’s reputation and case studies also played an important role.”

He expects the investment will improve productivity, enhance consistency, and reduce waste. He adds: “It will also allow us to take on more complex or higher-volume projects and support our growth plans over the coming years. While the system increases efficiency, it also opens up opportunities for new product lines and market segments, which could lead to additional roles in production, quality control, and support functions.”

The next generation Horizon iCE StitchLiner Mark V High speed saddle-stitcher completes the highest quality booklets in-line with continuous feed printers.
It runs at speeds of up to 6,000 booklets per hour. The sheets are tightly folded along the accurate scoring lines made one by one for consistent quality production without any special skill. Variable page count applications can be handled without any operator intervention. The in-line configuration insures sheet-to-sheet integrity.

It is equipped with iCE LiNK that uses cloud technology to automate workflow from upstream to post-press. It provides access to an intuitive, easy to use dashboard that reports real-time production analysis for improved efficiency and profitability, remote update capabilities and scheduled maintenance resulting in less downtime. The information is accessible via smartphone, tablet or desktop PC and the software is designed for integration with MIS systems.

As for expected return on investment Kevin states: “While specific figures depend on production volumes, we anticipate the investment will pay back within five years through savings in energy, maintenance, and improved efficiency.”

He concludes: “IFS has been an excellent partner – professional, responsive, and knowledgeable. The team supported us throughout the selection, installation, and training process, ensuring a smooth transition and minimal disruption to operations.”