Frequently Asked Questions

There are many factors to consider. As a general rule operation in-line with the printer/web cutter or the web unwinder/cutter is recommended if the booklet format size changes infrequently. Off-line operation from a pile feeder is recommended if a range of different book format sizes is needed.

Yes. This is done by selecting the feeder option SB-097 which provides the ability to feed the machine from a sheet pile feeder while retaining the ability to alternatively run in-line from the web cutter.

The maximum book thickness is 10 mm (0.4”).

The minimum book thickness is one folded sheet (4 pages), but producing very thin books may require the maximum sheet input rate to be reduced in order to avoid exceeding the maximum Smart-binder output rate of 116 cycles/min. Good quality paper stock, min 80 gsm (with grain parallel to spine), must be used if running single folded sheets (4 pages) through the Smart-binder to produce a document containing only 4 pages.

The use of options such as Loop stitching (LST-100), Folder (F-100 or RF-100), Center-knife option (CKN-100 or 101) and/or the Spine squaring option (SM-101) will reduce maximum book thickness.

Answer: The maximum input web speed (in-line or near-line operation) is 100 -130 meters/min without an extra buckle folder (4-page increments) This can be increased to around 180 metres/min with extra F-100 / F101 buckle folder (8-page increments). The F-200 selective folder is available to enable high web speeds while retaining 4 page increments.

The maximum speed when running off-line (from a sheet pile feeder) is around 400 sheets/min (a sheet normally contains 4 –pages, but may alternatively contain 8 or 12 pages if the extra F-100 / F101 folder is selected).

The maximum Smart-binder cycling speed for saddle-stitching is 7,000 cycles/hour or 14,000 books/hour (2-up). The actual booklet output rate is the sheet input rate divided by the number of sheets in the book (excluding a separately-fed cover sheet), providing this does not exceed 7000 cycles/hour (or 5,500 cycles/hour if using the SB-X.

The system efficiency depends on the complexity of the system (how many different elements are in use). For the Smart-binder itself (in-line or near-line), we suggest to plan on an operating efficiency of about 90%, unless it is being used to produce an unusual or difficult job which may reduce this running efficiency. Efficiencies in excess of 90% are achievable with some in-line Smart-binders running straightforward near-line job applications. Efficiencies slightly lower that 90% might be expected for an off-line Smart-binder due to the time needed to reload the feeder.

Small book formats can be easily produced in-line with a digital web printer by using a web which is double the book width (plus a little extra to allow for trim-off). However this web width may be much narrower than the printer maximum so in this case. It is more efficient for the printer to run a ‘wide’ web. In this case IBIS offer two different solutions to produce small format booklets from a wide web, RF-100 and TUSDC-100

Paper stocks as light as 40 gsm are possible, but using the Smart-binder sheets lighter than 50 gsm must normally be buckle-folded first using the optional in-line F-100 / F-101 / F-200 folder, before entering the Smart-binder infeed, or run at a much reduced speed. Maximum speeds may have to be reduced if running paper stocks less than 60 gsm without using the extra buckle folder.

The Smart Label-binder is a Smart-binder variant designed for 'Extended Content Label' (ECL) booklets production (as well as normal booklets) that can run paper weights as light as 37gsm without requiring the folder F-100.

Yes. The Smart-binder saddle-binder was designed to continually vary book thickness on-the-run and track each page using bar codes to ensure page sequence security. Each book can contain a different number of pages between 8 and 200 (if using IBIS's ISG cold glue binding system) or within a range of about plus/minus 3mm (if using wire stitching).

The Smart-binder cover feeder can be fitted with an optional Bar code reader BCR-105, or 2D code reader DCR-101, to ensure than each personalised cover sheet contains the same unique book ID number as the content sheets coming from the digital printer. If there is a cover mismatch then the Smart-binder will automatically stop and the touch screen will inform the operator of the reason for this stop.

After such a stop the operator must manually recover the correct cover sequence which will cause extra machine down-time. It is sometimes preferred therefore to feed covers with cutout windows which allow the personalized name and address to show through the window from the digital print on the first inside page. This ‘personalizes’ the booklet from the outside without requiring a personalized cover sheet.

The consumable cost of cold glue is generally similar to the cost of wire stapling (cold gluing is slightly cheaper when making thin booklets and slightly more expensive when making very thick booklets)

Yes the Smart-binder saddle-stitcher may be fitted with cover/insert feeder CIF-102 and an additional cover/insert feeder CIF-101. Feeder #2 may be loaded with the next cover while the current cover is feeding from feeder #1.

Alternatively, the additional cover feeder CIF-101 may be used to feed a pre-printed insert sheet at any position inside the book.

Note: if the insert must be in the center of the book (or is fed from the feeder CIF-101) then there must be a gap large enough between sheets coming from the printer into which to feed the insert.
Note: any inserted sheets will be bound into the book. If a loose insert is required then this must be inserted into the book using a separate post-trimmer inserter machine.

It depends on whether the optional CAL-101 ‘Cover Autoloader’ is fitted or not.  Without the Autoloader the max pile height is about 20mm, but this increases to about 200mm if the Autoloader is used thereby greatly increasing the time between reloads. The actual time between reloads depends on the running speed and the average number of pages in the booklets.  The thinner the booklet the faster the covers must be fed and the feeder must then be reloaded more frequently.

The SB-095 and SB-097 feeders can accept up to 5,000 - 10,000 sheets depending on the paper thickness. The time between reloads depends on how fast the machine is running and the average number of pages in the booklets.

The Smart-binder must be stopped to reload the sheet pile feeder. The reload time depends on whether one of the optional loading trolley systems, PLT-100 or HPL-100, is used or not. Allow for a few minutes to reload without the trolley system or about 35 secs with the trolley system (if trolley is already loaded in advance).

Yes. The optional DMP-100 Dynamic micro-perforator system may be integrated just before the Smart-binder folder. This allows any sheet to receive a perforation (perf) line at any position parallel to the sheet flow direction. A bar-code digit on each sheet controls whether that sheet is to receive a perf line or not. Each perf wheel is individually controlled so a sheet may receive a perf line on one side, but not the other side, or both sides together.

The DMP-101 system offers 4 perf heads instead of 2.

Yes. Both hole drilling and (lower cost) hole punching modules are available to be connected on-line with the Smart-binder delivery.

A single corner hold punch CHP-100 is also available to be installed inside the standard SB trimmer

Yes. The standard wire stitched heads may be exchanged for loop-stitch heads. In this case the stitcher drive upgrade LSM-100 must also be selected because loop heads require additional drive force.

Yes. A variety of stacking, wrapping and/or strapping/banding modules are available for direct connection to the Smart-binder delivery. See automatic book stackers BSS-10 or pile strapper PS-100

IBIS offers two different types of spine squarer, the SM-101 or the heavier duty ARSD-S-100, that can press book spines into a square shape and can be fitted directly to the Smart-binder delivery conveyor.

See section 9.9 of our Smart Binder Product Guide for more information

Yes. The Smart-binder has an optional center-knife system CKN-100, CKN-101, CKN-102 (with 6.3mm, 9.5mm or 0mm knife width respectively) which results in two booklets being delivered side-by-side. The minimum book spine length when using the 9.5mm trimmer center knife is 95mm. The maximum book thickness when using the 6.3 or 9.5mm trimmer center knife is about 3- 4mm, but this can be increased to 10mm if using the single-bladed center knife CKN-102 . If using the trimmer center knife when wire-stitching, then two extra stitch heads are normally required.

For normal one-up production the minimum spine length is 200mm. When using the optional center-knife CKN-101 for 2-up production then the minimum spine length is 95mm. The stretched model SB-X must be used if spine lengths are between 150 and 210mm.

The minimum book width is normally 119mm, but a special modification is available to reduce this dimension to 82.5mm if required

The standard Smart-binder can produce a maximum finished book size of 320mm (spine) x 230mm, less trim off.. The stretched model Smart-binder model SB-XW can produce a maximum book size to 457mm (spine length) x 273mm (width), less trim off.

The standard Smart-binder can produce A5 or 5½ x 8½" booklets in portrait format directly from a narrow web (320mm or 12" width) but it is inefficient for most web printers to print on a narrow web. The standard Smart-binder can produce A5 or 5½ x 8½" booklets in portrait format directly from a wide web (450mm or 18") by either using the RF-100 rotator/folder or the TUSDC-100 modules.

The standard Smart-binder can produce A5 or 5½ x 8½" booklets in landscape format 2-up using the optional trimmer center-knife.

The extended model Smart-binder SB-X can produce A5 or 5½ x 8½" booklets in portrait format 2-up using the optional trimmer center-knife.

Follow links below for webpages with more information.
A5 portrait | A5 landscape | 5½ x 8½" portrait | 8½ x 5½" landscape

The normal waste removal system is a simple inclined conveyor which delivers the trim-off paper strips into a customer-supplied collection bin.  Two different conveyor systems are available, for delivery into either a small bin (TWC-100) or a large bin (TWC-101).

If the customer has a factory vacuum waste extract system, then it is preferred to connect the Smart-binder to this instead of using the normal waste conveyor. In this case we supply a trim waste collector with a circular outlet for piping connection to customers extract system.

Any 3 phase voltage supply may be used, but voltages outside the 380 – 420 Volt range require the optional voltage transformer TFR-100.

The Smart-binder can be fitted with an optional book clamp system (TCA-100 / B0000586) that reduces or eliminates spine corner tearing.  This assembly is customized to suit a particular book width, so the book width must be specified when ordering this option.

Yes. The Smart-binder SB-1 range is intended for use with slower speed printers, such as cut-sheet printers. A sheet rotator and/or sheet direction changer may be needed in between the printer and the Smart-binder.

Note: Cut-sheet printers normally deliver large sheets short-edge leading and small sheets long-edge leading. The Smart-binder must receive sheets long-edge leading (for normal portrait format booklet production).

The condition of the paper is a critical factor in determining how well a high speed book-binding system will perform. Factory air conditioning is particularly important when external temperature and humidity is outside the normal range. Hot and dry paper will attract much higher levels of static charge which the environment must be carefully managed. We recommend to maintain relative humidity within the range 40-60% and temperature between 18 and 25ºC (64 and 77ºF).