by Cassandra Balentine
The latest printing and finishing technologies support print on demand (POD) through integration, data collection, and vision and inspection tools.
As publishers move from long to short book runs, modern equipment and associated workflows become essential to profitability and productivity.
Above: Standard is an exclusive distributor of automated print finishing solutions from Horizon International serving the inkjet, digital, and offset print markets in the U.S. and Canada.
As inkjet migrates from a “disruptor” to “core,” technology, Pete Dolfis, VP of sales, Tecnau, says the book production operating model is moving toward high‑automation, low‑touch production, making automated changeover a prerequisite for 24/7 POD. Plants that decouple capacity from headcount and reduce manual touchpoints are scaling more reliably amid labor constraints.
Unlike finishing equipment designed for the output coming off of cutsheet, toner-based print engines and single-shift production environments, current digital finishing and binding solutions are based off of proven conventional production machines to be robust and specifically developed to handle the higher speeds of today’s inkjet web presses, shares Mike Wing, solutions manager, Muller Martini/Hunkeler.
He adds that Hunkeler and Muller Martini technology have been utilized successfully for several years within some of the largest 24/7 production facilities across the world.
Bindwel’s 1NSTA is built for continuous POD use with servo-driven clamp movement, automatic thickness measurement/calibration, and automatic nipping parameter adjustments based on book thickness—reducing “operator dependence” during frequent changeovers.
Another example, all Horizon perfect binders are built on industrial frames and utilize robust high-quality parts designed for long-term use, even with frequent changeovers. Advanced automation simplifies adjustments and improves efficiency while reducing wear and tear caused by operator error.
Tecnau’s Revolution 50 AutoSetup is built for 24/7 duty cycles and executes fully automated, touch‑free changeovers between book impositions within a roll—keeping roll‑to‑book uptime high while insulating operators from frequent format swaps, adds Dolfis.
Challenges
One concern when handling variable-sized book runs is the “reconfiguration gap,” which is the physical space between two different books or the order on a finishing line.
Finishing flexibility has become a competitive lever, according to Dolfis. “Smithers projects books as one of the fastest‑growing inkjet segments precisely because configurable lines can vary format and pagination at full speed.”
The key to handling high-volume, variable-sized books is standardization. One way to do this is through rules-based automation, which is found in Muller Martini’s Connex workflow software to group production runs on press by factors like paper type, format size, and delivery date, to facilitate printing many short-run digital jobs back-to-back in the most efficient manner, comments Wing.
Another simple process for minimizing the reconfiguration gap in digital book manufacturing is standardization of the cover size. “Having a common cover size provides zero makeready on our fully-automated digital binders, which then allows for the full-variable trimmer to accommodate the different trim sizes without stopping and no human intervention,” says Wing.
On Bindwel’s 1NSTA, variability is handled through stored job recipes plus automatic format/thickness-driven settings rather than manual mechanical resets. “In practical terms, format changeovers from minimum to maximum—and vice versa—are designed to be under a minute when switching between stored settings/workflows,” explains Sajith Pallippuram, managing director, Bindwel.
The Standard Horizon BQ-500 covers all variations of the binding market including long runs, short runs, versioned books, and book of one. “A digital thickness caliper and 21 automated sections in the binder allow for quick, repeatable, consistent, and accurate changeovers. Additionally, customized templates are created based on paper type, desired quality level, and other criteria, allowing operators to produce consistent quality with greater production efficiency and quality control,” notes Ed Wehbe, product specialist, Standard Finishing Systems.
For book‑of‑one production, Tecnau’s StreamFolder adjusts page length within a fixed fold pattern—e.g., two‑up 9×12 inches, 8.5×11 inches, and 8×10 inches, saving substrate otherwise lost to a single 12.5-inch cut length. For short run/many, Revolution 50 AutoSetup reconfigures between two-/three‑/four‑up impositions in under 25 seconds, “shrinking the non‑productive gap while preserving pagination integrity,” shares Dolfis.
Communication is Essential
For short runs, communication between hardware and workflow tools is essential.
Stephen Sanker, national sales director, digital web, Koenig & Bauer US, Inc., points out that Koenig & Bauer directly integrates its digital printing machines with third-party finishing and web-folding systems for delivery of complete book blocks that can be integrated into various other systems. “We support direct digital front ends for integration into all workflows.”
All Muller Martini and Hunkeler digital finishing products can be directly connected to any MIS/MES front-end system to automate the transfer of data eliminating the need for equipment operators to read job tickets and/or rulers as data is sent directly to the machines. “This level of automation significantly reduces errors and waste, as well as minimizes set-up times and labor requirements,” says Wing.
Pallippuram explains that Bindwel has implemented a workflow interface where JDF job data can be interpreted via an executable (PC-side) component and passed to the binder over Ethernet, so the finishing step can be triggered with minimal manual entry at the machine. “If a workflow uses XJDF, the same concept applies—mapping required fields to the machine’s job template structure and pushing them over the network link.”
Most Horizon solutions, including perfect binders, are compatible with iCE LiNK, a cloud-based, postpress management system from Horizon. This solution can provide device monitoring, KPI analysis, PM schedule/alerts, JDF/JMF workflow support, scheduling, job creation, editing, and more. iCE LiNK also works with most MIS operating systems and interfaces with off-brand finishing systems.
Standard partners with Ultimate Technologies to offer Ultimate Bindery and Ultimate Impostrip. Ultimate Bindery is an open JDF server that validates jobs and delivers finishing job tickets to automate makeready on bindery equipment.
“It operates as an agent between prepress and post-press equipment to eliminate manual setup on the finishing device. Ultimate Bindery takes a JDF imposed job and completes it with all of the necessary parameters needed to automatically set up finishing equipment. Ultimate Impostrip prepress software optimizes and automates imposition workflow, with scalable options for high-volume production environments. An extremely easy-to-use yet versatile tool, it is a useful solution for quick turnarounds of short-run books,” shares Wehbe.
Dolfis explains that the industry supports two complementary automation patterns. “First, open job‑ticketing standards (JDF/XJDF + JMF/XJMF) for system‑to‑system integration. Second, robust, localized device control (including barcode‑driven). Many plants deploy both—XJDF where end‑to‑end automation is practical, and 2D barcodes when bulletproof, job‑by‑job control and error recovery are paramount.”
“We often favor 2D barcode control for POD books because recovery is automatic to the very next book, without queuing or operator intervention. Purely electronic signals can require queue management and manual verification after exceptions; barcodes keep production flowing while still coexisting with MIS‑level XJDF where customers want it,” confirms Dolfis.
Overcoming Failure
Sensor and scan technologies are implemented to reduce errors in matching covers and book interiors.
Josh Howard, senior director, Inkjet Research & Development, Kodak, shares that the Kodak PROSPER Presses have a patented, camera-aided KODAK Intelligent Print System (IPS), which minimizes waste and ensures consistently high output quality by continuously monitoring and evaluating system operation. It measures and optimizes stitching, color-to-color and front-to-back registration, and color density uniformity across jetting modules, making up to five real-time adjustments to the image data on every printed page, and providing a visual monitoring system for operator inspection.
The newest generation of Horizon perfect binders come equipped with barcode readers and inline integrity solutions. “Verification and integrity software can perform sheet, signature, and book block-level tracking as well as cover-to-book block matching. Depending upon the configuration, these systems can reject incomplete book blocks or book blocks with the pages out of order. In this case, the rejected book block is identified and can be used to generate a reprint file. In the case of a mismatched cover and book block, the binder will alert the operator for correction or ejection. Inspection systems are integral in guaranteeing product quality without increasing labor costs,” comments Wehbe.
Muller Martini solutions incorporate the latest camera-based scanner technology in all of its digital solutions to ensure that the book blocks are complete—the front and back page are intact and match, the book blocks and covers are in the right sequence, and the content and covers match before the products even enter the binder. Wing says this allows for automated re-sequencing or product ejection from the machine without stopping production or wasting any materials.
The failure rate of matching colors and interiors varies heavily by practice, and upstream print consistency. “To reduce mismatch risk, 1NSTA supports quick response (QR) code/barcode-based cover recognition and a reject path if the cover doesn’t match the book block—so errors are intercepted before they become finished goods,” offers Pallippuram.
Look to Data
Certain print and finishing equipment provides overall equipment effectiveness by tracking data like cost per unit.
Wehbe points out that finishing equipment integrated with Horizon’s iCE LiNK postpress management system is able to send performance and operational data such as cycles per hour, total uptime, total throughput to the cloud for analysis. “Operators and managers can see which machines are operating most efficiently while identifying where bottlenecks are occurring.”
In addition to the capability of imposing files for the digital presses or automating the set-up of finishing equipment, Wing says the Muller Martini workflow software also has a data collection suite of modules that automates the data collection process and provides meaningful real-time KPIs for performance analysis and effective business decisions.
Bindel’s 1NSTA addresses digital/POD variability using automatic adhesive-layer control and programmable parameters such as notch interval, on approach to be tuned per job/substrate. In addition, the gluing unit supports an interchangeable trolley-type glue tank for EVA and PUR, enabling customers to select adhesive chemistry appropriate for coated/digital surfaces and durability requirements.
Adhesion Considerations
In a digital book line, binding equipment helps manage gluing adhesion challenges on digital inks and toners.
Flexibility is key to tackling this challenge. Wehbe says Horizon binders support a variety of gluing solutions for various paper stocks, offset inks, and coatings as well as digital inks and toners.
Dolfis adds that PUR remains the reference adhesive for challenging substrates, coated stocks, and long‑life books because it chemically crosslinks, maintains flexibility, and resists reactivation at elevated temperatures—where traditional EVA hot‑melt can weaken.
Due to the diversity of substrates, inks, coatings, and printing technologies; today’s perfect binding solutions need to be flexible. Wing states that Muller Martini has developed highly automated binders that incorporate integrated and exchangeable glue application systems to allow book manufacturers to effectively determine which adhesive is optimal for their process.
Tecnau’s Libra 800 perfect binder supports hot‑melt, PUR, or hybrid application—e.g., PUR on the spine with hot‑melt on courtesy scores for fast set. PUR’s resistance to heat‑induced softening keeps bound books intact even in warm ambient conditions—think “book left in a car”—while still allowing cycle‑time agility, shares Dolfis.
Battling Heat Curl
Heat curl, the warping or bending of paper, is an upstream print/media issue caused by heat and pressure from the fuser.
“Curl in digital/inkjet contexts stems from moisture and solvent migration and fiber‑bond changes during wetting/drying; research ties permanent curl to fiber–fiber bond rearrangements and solvent gradients across the sheet. Practical countermeasures include web‑tension control, decurling modules, moisture management, and alternating fold strategies to balance felt/wire side tendencies,” says Dolfis.
Tecnau’s Revolution 50’s taut‑web platform gives it precise web steering via edge sensors, ensuring perforations align squarely with minimal skew. “An operator‑adjustable decurl assembly —both directions from neutral—and buffer dancers that can release tension during idle periods help flatten the web. StreamFolder’s plow‑folded signatures inherently alternate felt‑/wire‑side curl sheet‑to‑sheet, improving layflat at the book block. Industry guidance also supports active decurl strategies on digital presses where available.”
Technologies like Canon’s ColorStream allow printers to efficiently produce, personalize, and cost-effectively print book sin small or large volumes.
The KODAK PROSPER utilizes distributed inter-station drying with an intelligent, near-infrared (NIR) drying system to immediately dry the water-based inks between the color stations. “The combination of fast-drying inks and advanced drying technology means PROSPER Presses manage with comparatively low energy requirements for drying, which minimizes heat stress on the paper and thus moisture loss—a major cause of paper curl. The paper path and a festoon with cross-ventilation after the second printing tower also contribute to the thermal relief of the paper,” shares Howard.
The HP Indigo 120K Digital Press is designed for high-volume, automated book production, offering 6,000 sheets/hour B2 speed, non-stop printing, and 90 percent uptime, according to the company. It boosts book production productivity by 33 percent using AI-driven automation, continuous feeding/stacking, and seamless integration with finishing equipment for automated, end-to-end workflows.
Managing Labor
As technology advances, the need for skilled operators is ideally reduced to help ease labor demands.
Dolfis stresses that labor remains a structural constraint and the industry response has been deeper automation from imposition to packaging, making “one operator per line” increasingly attainable when upstream job submission and downstream handling are automated. “Trends at inkjet and finishing conferences emphasize touchless workflows, automated splicing/roll handling, and conveyorized finishing to lower staffing ratios.”
Given today’s press speeds, Dolfis suggests uninterrupted material flow is the bottleneck. “A zero‑speed splicing unwind—e.g., Tecnau u55—widens the time window for roll changes. When the line carries glued book blocks directly through bind/trims and into a Tecnau | Sitma packaging cell (with print‑to‑ship logic), one operator per line moves from ‘ambitious’ to ‘operational.’”
Pallippuram says the road to one operator is increasingly a reality—especially when setup and repeat jobs are recipe-driven. “The biggest obstacle is usually not binding complexity, but rather job variability and discipline in upstream handoff—correct barcode/QR usage, consistent trimming/stacking logic, and stable print conditioning. With automated templates, scanning/verification, and ergonomic delivery, single-operator POD binding and trim-on-demand cells are practical in real production.”
The biggest obstacle Wehbe sees is at the in-feed and delivery sections where it is difficult for a single operator to manage both ends. “However, robot-assisted solutions are entering the market that are easing the burden on operators by letting them focus on operational tasks rather than feeding and collecting.”
The technologies—e.g. artificial intelligence, robotics, equipment, and workflow automation, etc.—exist today for a true Smart Factory. “However, the biggest obstacle that most POD customers face is the initial investment cost to develop a viable solution that is flexible enough to be operated by a single person,” notes Wing.
Howard explains that KODAK PROSPER Presses are designed for high-volume, continuous production and can be operated by a single operator per shift. “This lean operation is made possible through high levels of automation and intelligent monitoring systems. The press operator is primarily responsible for starting jobs, monitoring, and managing automated print modes.”
A prime example is Mercury Print Productions in Rochester, NY, a Kodak customer and educational book printer that operates several PROSPER Presses, including the PROSPER 7000 Turbo Press. “According to the company’s CEO, John Place, all of these presses run 24/7 and are supervised by just one operator per shift,” cites Howard.
Koenig & Bauer’s production is enabled with minimal labor in comparison to other printing technologies. “We build all RotaJET systems to the specification of each customer, so we have the modularity to vary the web-width for each machine. The RotaJET system is operated by one person with support for material handling at either end of the machine. As a result of the efficiencies of the machine, our customers experience a reduction in overall labor, inventory, and fixed costs associated with high-volume book production at the highest levels on a wide range of paper types and extremely light paper weights for optimal performance,” shares Sanker.
Book Automation
The book market is shifting from scale to responsiveness with shorter average runs, volatile frontlist, resilient backlist, and tighter replenishment cycles. “Publishers raise quality expectations while leaning on digital inkjet for faster turnarounds and inventory risk reduction. Industry data shows production inkjet keeps expanding its share as workflows are optimized for print on demand, with flexible finishing that varies formats at press speed,” concludes Dolfis.
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May2026, DPS Magazine
