Books International Text Printing
Cut Sheet Printing
Welcome to Books International text printing.
Visual: Video transition into stacked books
In our cut sheet area, we have four presses, one toner machine, and three ink-jet color machines.
Visual: Books International logo fades into inside printing plant
We have an i300 color machine, and also in addition, we have two IX, latest generation Canon inkjet color printers.
Visual: Different shots of machinery inside printing plant
All cut sheet work has to be trimmed and separated for the binding.
Visual: Machinery and employee using machinery to cut stacks of paper
Web Presses
On the role side, we have two web presses.
Visual: Video transition to HP T240 machinery in the background
A T240 20 inch machine and a T490 40 inch machine.
Visual: Video transition to HP T240 machinery
What you see here is the T240 color inkjet press.
Visual: Paper with color graphics rolls off the HP T240
That press delivers into a finisher and a stacker.
Visual: Video transitions to view of internal machine components
The finisher folds signatures into 8, 16, or 24 page signatures, and then collates those signatures into a stack which is glued together for the bindery.
Visual: Views of the machine's various moving components
Those stacks deliver at the end of the collator to be palletized for the bindery.
Visual: Transition back to inside printing plant
Next you see the 40 inch digital web press.
Visual: View inside a different part of the printing facility
What we call a T490. It's black only, running at a thousand feet per minute on 40 inch wide paper.
Visual: View of the machinery
The press is connected to a Muller martini folder and stacker.
Visual: View of printing area with workers using computers
We are printing eight to 32 page signatures on this press, which are collated, folded, and glued into book blocks.
Visual: Inside a printing device, a sheet of paper is pushed out as the machine turns
Those book blocks are palletized and delivered to the bindery.
Visual: Stacks of paper slowly come off the machine one at a time
What you see here is the folder, two folder boards, building the signatures, going into the stacker, and then delivering the book block to be palletized for the bindery.
Visual: View of machinery and workers
Cover Printing
Welcome to the cover printing area.
Visual: Video transition into stacked books
We have two Indigos for our cover printing.
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Indigo 7800 and an Indigo 12,000.
Visual: Printing machinery in printing plant
All our covers print on the Indigos: Jackets, case bound covers, and paper bound covers.
Visual: An Indigo printer and worker preparing the printing paper. On screen, text in rainbow order shows "Indigo 12000"
The range is usually from 80 lb. paper stock to a 14 point cover.
Visual: Video transition to a different Indigo printer
The stock's been loaded by the operator manually, then he performs his quality checks and then he starts running the press.
Visual: A man works with an Indigo printing machine
The press delivers pallets of product to be delivered to the bindery for lamination.
Visual: Video transitions to a different Indigo printer
He also performs quality checks throughout the run as you can see right here.
Visual: The same worker as before is checking print quality
We also have a MGI media press.
Visual: View of another machine in the facility
This press is utilized for printed oversized sheets.
Visual: The screen text displays "Meteror"
Press is capable of running sheets up to 40 inches.
Visual: Inside the machine, a brown sheet runs along the platform
We also use this press for our case bound printed foil process.
Visual: The words "COLLOSAL AMBITIONS" appear on a printed page
We print black only on the case material and that case material then is foiled in this machine.
Visual: Machine prints text onto a brown case sheet with silver foil
POD Binding
This is our POD binding.
Visual: Video transition into stacked books
We use barcode capability on all of our POD equipment.
Visual: Interior of printing facility with various pieces of equipment
As you can see here, the Vario Binder is reading the barcode and then matches the cover to that barcode and also utilizes that barcode for the make ready.
The operator inserts the material and then the barcode takes care of the make ready and makes sure that the cover is matching the book block.
Visual: A worker pushes a book into a piece of machinery
The operators simply feed the book block, the camera beneath the clamp is reading that barcode, and sets up the machine automatically to whatever size is required.
Visual: Two separate printing machines are shown
You can see the cover delivery right here.
Visual: View of a book going through printing machinery
Again, automatic make ready and adjustments are being made from book to book.
Visual: Camera transitions to a side-view of the machinery
All covers are cut to the same size, and the book block underneath is what changes.
Visual: View of the stacks
This is our ODM casing in machine.
The ODM is a single wing casing in machine with a building in, which we use for our book of POD production.
Visual: A woman puts a book into printing machinery
Quality Control
This is the quality control area.
Visual: Scene changes to a different area. A worker reviews the stack
All books are inspected before they are delivered to the client.
Visual: A long aisle of shelving and machinery in a printing plant
As you can see, the operator checks the books, checks the jacket, make sure the book's encased in properly, and then checks those materials against our job work instructions.
Visual: Books are carefully reviewed by the worker
Case Making
This is our Kobus case maker.
Visual: The last part of the production and packing is shown
All cases, quantity of 10 books or more, are produced on this machine.
Visual: Zoomed view of machinery in print factory
The machine combines the boards and the cover liner with the printed material, which can also be a foil stamped material.
Visual: Inside the machine, an image appears of the equipment
Casing-In Line
This is our casing in line.
The operator feeds book blocks into a pre-heating tunnel to provide us the opportunity to get as much round into the book as possible.
Visual: Long assembly line with moving parts and workers. Boxes filled with product moving through production
You can see here the in feed into the round backer.
Visual: View of internal components of machinery
Then we apply hot melt to the spine and after that we apply head bands and reinforcement material, and the case onto the rounded book block.
Visual: Inside the machine, components begin the process of packaging the product
Those books are then delivered into a stacking system which then are delivered to a final quality inspection and stacked onto cards to be delivered to shipping.
Visual: A stack of products moves from one part of the assembly line to another
This is the quality control area.
Visual: A different area is shown. Books are inspected
All books are inspected before they are delivered to the client.
Visual: The operator checks the design and color
As you can see, the operator, checks the books, checks the jacket, makes sure the books encased in properly, and then checks those material against the job work construction.
Visual: The design and construction of the books are carefully reviewed
Trim size is checked.
Visual: The dimensions of each book are confirmed to specification
The next section we are going into is POD Binding.
Visual: Books are packaged and placed on the assembly line
Warehousing
All books which are not shipped directly to the client are placed in one of our warehouses.
Visual: Machinery in a warehouse
We have five warehouses for a total of 250,000 square feet available.
Visual: Boxes transported by a forklift in warehouse with numbered aisles
All warehouses are set up with wire guided forklifts and all books in the warehouse are barcoded to allocation.
Visual: Video transitions to interior view of warehouse
As books are picked or delivered into locations they all get scanned by the operator.
Visual: A conveyor belt moving through a vast distribution center