What does the machine do?
Morgana’s BM500 bookletmaker is a stand-alone offline adaption of a system it originally developed to run inline with a digital press. It’s a modular system that staples, folds and trims pre-collated sheets and has various options for extended functionality and automatic feeding. The company says it was developed to meet a growing demand for either higher page-count booklets or booklets made from thicker stocks.
The BM500 is the larger capacity version of a pair of models currently on offer, able to accept up to 50 flat sheets of 80gsm paper to produce 200pp booklets. The BM350 can produce up to 140pp booklets from 35 flat sheets. Previous Morgana bookletmakers have been intended for thinner books from up to 30 sheets. Since the company’s acquisition by Plockmatic in 2013 it has extended its bookletmaking range with new technologies.
When was it launched?
The BM500 was launched in the UK as an offline unit in May of this year. However, a version of this machine has been available for more than 18 months as an inline add-on for both Xerox and Ricoh digital presses.
How does it work?
The simplest configuration is just the BookletMaker and output tray to process hand-fed sets. However Ray Hillhouse, vice-president of offline business at Morgana Systems, says that most systems to date have been supplied with at least the FTR500 face-trimmer module as well. This removes the shingled effect on thicker documents and provides a clean edge.
Handfed machines can have the SQF (square-fold) unit attached as an option. This creates a square spine for a perfect bound appearance that allows books to stack flat and also to have spine lettering.
Where higher volumes are needed, it can be equipped with one of two feeders: the ACF510 or the high-capacity AF602. Hillhouse says: “The 510 is used where there is also a need to collate flat sections from a litho or digital press, whereas the AF602 is used for pre-collated digital applications.” A belt stacker is also available.
New adaptive folding technology measures the book’s thickness and automatically adjusts the fold roller pressure, the trimmer and square-fold unit if fitted. Staple and fold positions are calculated automatically although they can be adjusted on the touchscreen on the run.
How does it differ from previous models?
“The key difference in the BM500 from previous models is its ability to produce really thick booklets,” says Hillhouse. The automation to do this is also new, he says: “The machine can go from 50 sheets of 80gsm to five sheets in the next set with no operator intervention. The bookletmaker measures the thickness of the set and adjusts to suit automatically.”
How productive is it?
Throughput depends on what you’re giving it – the larger the sheet size and more sheets per set the fewer it produces and vice versa. “The big advantage is when running with one of the feeders like the AF602 it can be loaded with up to 570mm of paper and set running,” says Hillhouse. “The system will basically run until it’s empty, allowing the operator to get on with other things. The AF602 can also be loaded on the run for longer run jobs.”
What is the USP?
“I would say it is the ability to produce the thick books with square-fold spines at a very competitive price” says Hillhouse.
How easy is it to use?
Very easy, says Hillhouse: “When the machine was designed it had a complete new touchscreen interface giving graphical support to each function.” All functions are controlled from the screen, including the optional modules.
What training and support is on offer?
Morgana handles all training and support, says Hillhouse.
How much does it cost?
Systems range from a basic hand-fed BM350 at around £8,500 to fully configured systems at over £40,000.
What is the sales target?
“We are expecting over 20 systems to be installed in the UK this year,” says Hillhouse. “Currently there are over 600 units installed, including the inline versions of the machine.”
SPECIFICATIONS
Paper sizes 206-320mm width, up to 457mm length
Standard sheet sizes A4, A3, B4, SRA4, SRA3
Paper weight From 64gsm (uncoated) or 105gsm (coated) to 300gsm
Set size (stapled folding) 2-50 sheets BM500 (80gsm)
Set size (non stapled folding) 1-2 sheets
Optional trims 1-16mm (single trim)
Footprint From 810x720mm (up to 3,930x720mm with all options)
Price Fom £8,500 to £40,000-plus
Contact Morgana System 0800 1381 882 www.morgana.co.uk
ALTERNATIVES
Duplo 600i Booklet System
This is intended for high-volume digital and offset work. It’s a fully automated stitch-fold-trim solution combining DSC-10/60i Collator Towers and DBM-600 bookletmaker and trimmer. Suction feed with ultrasonic detection is standard. A slit-cut-crease module and three-knife trimming are optional.
Max thickness 3mm (30 sheets of 80gsm)
Min paper size 105x297mm
Max paper size 350x508mm or 230x610mm
Finished booklet sizes 105x75mm-350x254mm
Footprint DB600i with DBM-400 STR Stacker and DKT-200 Trimmer 8,400x929mm
Price from £77,000
Contact Duplo International 01932 263900 www.duplouk.com
CP Bourg BM-e
The BM-e bookletmaker handles stitch–fold–trim for up to 30 sheets (75gsm) to make 120pp documents, with saddle or top/side stitching. It can be connected to either a collator for offset print or to the company’s versatile BSF digital sheet feeder.
Min paper size 119x180mm (saddle stitch) or 190x170mm (top/side)
Max paper size 370x600mm (saddle) or 370x300mm (top/side)
Paper weights 60-350gsm
Saddle stitching thickness 2-39 sheets (75gsm) including fold, cut and cover
Top/side stitching thickness 2-55 sheets (80gsm)
Price £25,000 to £85,000 depending on spec
Contact Integra 01420 593680 www.igm-group.co.uk/integra
USER REVIEW
“Our customers were requesting a booklet finish for higher page counts with a superior finish rather than the standard saddle staple. The system, installed in June, is already serving us very well. The SquareFold and trim is a great facility giving a superb finish. It offers something different for the market.”
Brian O’Loughlin Group director, Hacketts, Cork, Ireland (BM350 user)
