The optional F-100 pre-folds sheets before they enter the Smart-binder infeed. The folder may be used either to produce small format books, increase SB page throughput, or reduce input sheet rate.
When using the F-100, then sheets are printed with 4 pages on each side (instead of the normal 2 pages on each side when not pre-folding). These 8-page sheets are then folded by the F-100 across the middle ('buckle'-folded) before they enter the SB and are folded again in the opposite direction by the SB plow-folder.
For example: to produce A5 (Digest 5 ½" x 8 ½") books, print oversize A3 sheets (or oversize 11 x 17"). These sheets must enter the F100 short-edge leading. The folder then folds the sheet in half to give an oversize A4 (or oversize 8.5" x 11") section with the folded edge leading. These folded sections then enter the Smart-binder and are processed normally thereafter into finished A5 (or 5 ½" x 8 ½") books.
To produce A4 (or Letter - 8 ½ x 11") books, print
oversize A2 sheets (or oversize 17 x 22"). These sheets must
enter the F100 short-edge leading. The folder then folds the sheet
in half to give an oversize A3 (or oversize 11 x 17") section
with the folded-edge leading. These folded sections then enter the
Smart-binder, and are processed normally thereafter into finished
A4 or 'letter' size books.
Since sheets are folded into sections before entering the Smart-binder, and books can only be made from whole sections, it is only possible to make books with pages in multiples of 8-pages when using the F100 folder.
Folded sections are more bulky than flat sheets, so this technique
may also reduce the maximum number of pages in the book.
The folding process may be deactivated when it is required to pass 4-page sheets through the F-100 without folding. The F-100 folder may be fitted with optional anti-static bars to reduce the static charge on the sheets delivered to the Smart-binder.
When using ISG gluing together with pre-folded sheets, then a second cold-gluing nozzle must also be installed in the folder, option FGS-100, (to place a line of glue inside the folded sheet).
The F-100 enables the max web speed to be increased to about 150
metres/min or, if running from a sheet feeder the maximum page throughput
can be increased. The F-100 also allows the minimum paper weight to
be reduced to approximately 40 gsm (at reduced web speeds).