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When Watkiss Automation built a specialist application for a customer in the mid-1990s, it can’t have imagined the unique set-up would evolve into its Document Finishing System (DFS), which would go on to sell to 300 printers around the world after its 2001 launch.

 "The customer needed to regularly produce 27,000 12-page personalised reports, each one different," explains Jo Watkiss, communications director at the family-owned Bedfordshire-based manufacturer. "The sheets were sequentially printed on a digital printer and assembled, stitched, folded and trimmed on a Watkiss system. This is a commonplace today but at the time there was no other solution."

 Aimed at the digital print market, the DFS is a completely modular system, so comes in a number of different configurations, with a roll call of bookletmakers (stitch-fold or staple-fold), between 2 and 8 feeders, the SpineMaster SquareBack finisher, a connecting bridge, and barcode readers to choose from.
 
Smooth operator
For near-line units, pre-collated sheets are taken from the printer and loaded into the machine. Additional sheets – such as inserts or cover stocks, which may have come from another print source – are also loaded. When the machine starts, it feeds the sheets into a hopper until the set is complete. The set is then released into the bookletmaker. A barcode reader can be used to control variable sets and provide absolute set validation. Alternatively, the operator programs the required number of sheets and inserts per set. You can also incorporate the machine online, according to Watkiss.

 "When the DFS is online to a printer, the sheets are conveyed directly from the printer through a connecting bridge and into the hopper," she explains. "If necessary, the sheets are rotated into the correct orientation for bookletmaking."

The technology is based on the Watkiss Vario collating system, and uses the SlimVAC variable profile rotary suction feeder with air separation. The option of multiple feeders gives the system real flexibility as the machine can finish both pre-collated and batch-printed sets, while multiple inserts are possible. An anti-static system, meanwhile, ensures reliable paper handling of digitally printed stocks, while sheets are loaded and unloaded from the same position, giving an important logistical advantage for the operator.

 A wide range of paper types (40-240gsm) can be accommodated in all feeders, and these feeders can be loaded on-the-run to enable continuous production.

 Watkiss Automation does offer part exchange and can offer the occasional secondhand DFS. The company also offers a number of different service contracts for the system.

"As we are a UK manufacturer, spares are all held in stock and orders before 3pm are despatched same day," she adds. "Field engineers also carry key spares in their car-stock. We also have engineers based at HQ for telephone technical support across the country."

 Watkiss advises buyers to view a potential secondhand DFS purchase in action to make sure it is functioning. "We provide an inspection report and quote for refurbishment, installation and operator training if requested," she adds.
 A used system is roughly half of the price of the equivalent new machine. A new configuration of 4 SlimVAC feeders with bookletmaker and SpineMaster costs around £34,145.

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SPECIFICATIONS
Speed
A4: up to 6,400 sheets/hr?
A3: up to 5,200 sheets/hr
Booklet production
Automatic Stitch-Fold & Trim: 3,300/hr?BookMaster Pro: 2,500/hr
Typical production rate
10 sheets A4: 6,000sph?10 sheets A3: 5,000sph
Feed bin capacity 45mm
Stock size 148x210mm-320x482mm with BookMaster; 148x210mm-350x482mm with automatic Stitch-Fold & Trim
Stock range 40-240gsm
Dimensions 2.08m (l)
Price
New 4 SlimVAC feeders with bookletmaker and SpineMaster: £34,145?Used: from £17,000
What to look for
• Service history