Guide to Printing Sheets for Smart-binder Processing

 

 

 

A) Sheet Sequencing

 


Note: The first sheet to enter the Smart-binder needs to be the center sheet of the booklet. The center two pages on this sheet should be facing downwards

  1. Sheet sequence for in-line operation

    (Smart-binder fed directly from a printer and web cutter): The first sheet to be printed should be the center sheet of the booklet

  2. Sheet sequence for near-line operation (roll to roll printing: Smart-binder fed from a pre-printed roll)

    If printing roll-to-roll then the first sheet to be printed will be the last sheet to come off the roll when used to feed the IBIS Smart-binder. This means that the first sheet to be printed should be the outside (cover) sheet of the booklet.

  3. Sheet sequence of off-line operation (feeding the Smart-binder from a sheet pile feeder)

    The sheet feeder feeds off the top of the pile, so the top sheet must be the center sheet of the booklet.
 

B) Codes to be printed on each sheet

 


Every sheet requires a bar code (or 2D Datamatrix code) printed on it which contains at least 8 digits. Digits 1 and 2 must show the number of the sheet in the booklet (first sheet 01, second sheet 02 etc.). Digits 3 and 4 must show the total number of sheets in the booklet (02 for a 2-sheet booklet and 03 for a 3 sheet booklet). Digits 5-8 should all be zeros assuming that no further data needs to be contained in the code. That means if making a 3-sheet booklet then the 3 sheets should have the following codes on them:

01030000
02030000
03030000

Additional Digits may be also be used to automatically control certain special Smart-binder functions if needed. Digits may be added to show a job number or booklet ID number if needed. Refer to the IBIS Bar Code Guide for further details.

If feeding a personalized cover from the cover feeder CIF-102 then the cover also needs a code printed on it which must contain the same ID number as printed on the inside sheets. The code on the cover should be 0000 plus the booklet ID number. The Smart-binder will then stop automatically if the cover ID number does not match the sheet ID number.

Code position when feeding a Smart-binder directly from a web cutter (or from a sheet feeder with the code reader positioned on the Smart-binder infeed)

The bar code (or 2D Datamatrix code) on each sheet needs to start at least 6.7" from the leading edge of the sheet. This bar code should be very close to the right edge of the sheet and facing upwards as the sheet feeds into the Smart-binder.

Dimension Linear code 2D code
(1) Minimum distance from leading edge of sheet 170mm (6.7") 170mm (6.7")
(2) Maximum distance from leading edge of sheet Up to trailing edge of sheet 240mm (9.4")
(3) Minimum distance from edge of sheet Can be printed to edge of sheet Quiet zone defined for code
Minimum width Depends on which reader is used  

 

Code position when running off-line from a sheet pile feeder (SB-095 or SB097) with a code reader mounted in the feeder

Each sheet needs to have a bar code printed on it which is positioned at least 80mm from the leading edge of the sheet. This bar code should be 2mm from the right edge of the sheet and facing upwards as the sheet feeds into the Smart-binder.

Notes

Minimum code width depends on the reader used.

* Codes must be printed a small distance away from the edge of the sheet. This is because the sheet moves slightly as it is picked up by the separator and this can expose the code on the sheet below, hence preventing the reader from decoding the code on the top sheet.

** The code must be positioned no more than about 25mm from the edge of the sheet. This is because there are parts of the feeder which prevent the code reader from being moved to these positions. Normally the code is printed close to the edge fo the sheet so that it is removed by then Smart-binder front knife cut and not therefore visible in the finished booklet.

 

 

C) Sheet quality


Bar codes must be printed with high enough print quality to enable them to be read by the Smart-binder code reader at high sheet velocity.

Sheets to be fed into the Smart-binder must not contain high levels of static charge, must be flat (not curled) and must not be physically damaged in any way.

Paper stock weights should normally be 60gsm or higher, although paper weights as light as 50 gsm may be used, subject to testing. Paper weights below 50gsm may require use of the optional additional in-line buckle-folder.

Sheets that are heavily coated (glossy stock) may not be suitable for ISG cold glue binding (subject to testing). Booklets made from this type of stock should be wire stapled.

Sheets that are printed to stack, for subsequent feeding into the Smart-binder using the optional sheet pile feeder (SB-095, SB-096 or SB-097) must all be the same format size and must be accurately registered to the rear edge of the pile in order to allow reliable feeding.