Leading UK book printer, Bell & Bain’s 185 year print production journey has returned it to its roots of short run book production. The full-circle was closed with the commissioning of the world’s first Horizon Smart Binding System supplied by Intelligent Finishing Systems, running inline with a Fujifilm Jet Press 540W colour inkjet web press.

Managing Director Stephen Docherty explains: “When the business was established it was a specialist in short runs. As the industry changed so did Bell & Bain with the ability to offer economical medium to short runs. Today customers need operations to offer them a full range of digital and offset capabilities with all that entails. The Horizon system was perfect for that and will allow us to deliver highly responsive short runs and even books on demand.”

Bell & Bain reviewed the available solutions before replacing an existing Muller Martini Sigma binding line with the Horizon Smart Binding System. The Horizon Smart Binding System is modular in design and has been configured with a Tecnau 530 buffer, c20 cutter, s20 stacker and 568 feeder for configuration inline to their Fujifilm JetPress 540W.

“As soon as I saw the Horizon Smart Binding System I knew it was what we needed,” comments Docherty. “It was the best binding quality that I have ever seen.”

He continues: “The fact it was a single line means it requires much less operator intervention. It is also faster and easier to set up which was a bonus for our capacity and productivity. It was definitely the right way to go. It just does what it is supposed to do. Now I can see what the scope is and what it can help us achieve. We will be able to push a book on demand service. Customers have also noticed a difference and commented on the quality.

“Another benefit we found early on is that we can lift work off and put a short run job – even litho – through it. That makes production very flexible. It is the Holy Grail because we can finish runs of any length and interrupt work for rush jobs. Printing on a digital web also reduces waste and eliminates any unnecessary costs. There was a learning curve as you would expect but this was quickly achieved to allow us to see the full potential.”

The Horizon Smart Binding System consists of four key elements; signature folding, stacking with pre-gluing of each book block, variable perfect binding with automatic cover and book block matching and variable three-knife trimming by dynamically reading a barcode on every book cover. For even more production flexibility, cut-sheet stacked output is enabled by the Tecnau c20 cutter, s20 stacker for other products and digital sheet input to the Smart Binding System is also possible by using the feed table and automatic feeder on the signature folder. The signature folder can be quickly changed from inline to near-line.

It runs inline to Fujifilm Jet Press 540W colour inkjet web press. Mark Stephenson, Fujifilm Product Manager, Digital Printing and Press Systems, Graphic Systems EMEA adds: “It has only been a few months but the installation went well and the combination is making an impact. Any teething points were quickly addressed as all parties worked closely together quickly and highly effectively. Bell & Bain will now be able to enjoy a fully integrated, streamlined end to end process.

Docherty concludes: “It has secured our future. We don’t have a three year or a five year plan. We just do what we believe to be right for the business when we believe it. We have the equipment to produce the best and give our customers what they want.”