Trouble with Digital Jobs -- Collator/Bookletmaker

Discussion in 'Collator-Booklet Maker Systems' started by jpfulton, Sep 18, 2014.

  1. jpfulton

    jpfulton Member

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    We are running more and more booklets that have digitally run covers with heavy toner cover on our Standard Duplo 12/24A. We are having a lot of trouble getting them to run well. The problem is usually not at the bins but later down the line. We are using either 65# Uncoated cover, 90# Index or 110# Index. We've tried switching up stock to help the problem without a whole lot of difference.

    Problems:
    1. The folder is often the problem -- where the rollers/wheels are supposed to pick up the book to fold it in half, the rollers/wheels will slip.
    2. Sometimes at the delivery unit there's a problem -- the wheel that is supposed to roll over the top of the book assist with the exit along the conveyors just slips and a jam is caused.
    3. I'm not the operator so I can't say exactly, but I think we also sometimes have problems just as the sheets travel horizontally through the machine. Sometimes it will skew causing the fold to be crooked, face trim crooked or just regular old jams

    Between me, our operator and my boss we are somewhat handy and manage to band-aid a lot of problems with rubber bands, tape, paper clips, WD40 etc but this is one that we haven't really solved.

    Is this a known issue on older collators? Are newer collator/bookletmakers designed differently to accommodate digital jobs? Again, this is not even a problem with pickup in the bins.

    Thanks!
     
  2. Lcegraphics

    Lcegraphics Member

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    In order to produce Slick surfaced booklets you have to have hard rubber fold rollers like the new Duplo Systems have.
    The bookletmaker you have has steel fold rollers which are OK for uncoated stocks but they can slip on Uncoated.
    We can supply Hard rubber rollers to replace your original steel rollers. Lce Graphics
    Also there is another way. You can use a special tape called Tesa Tape. This has been used for years to provide more grip on folder rollers.
    Just apply this tape to the first set of rollers in a forward spiral to the outside of the rollers. Do not overlap but allow at least 1" space between wraps.
    As far as feeding is concerned on the collator you will need to use a Gel Type feed roller or make sure the roller is new and not dried out from age.
    Also you can use an air nozzle with a small compressor to blow air into the paper stack. This helps with static and allows the sheets to separate and feed more easily
     
  3. jpfulton

    jpfulton Member

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    The system we have has black fold rollers. They are very hard and are kind of shiny. Are those the steel ones or the hard rubber ones? (I would assume those are the hard rubber ones).

    So we'll probably give the tesa tape a shot. If I understand correctly we should wrap the tape around both bottom rollers in a spiral pattern with 1" between each wrap?

    Thanks!
     
  4. Lcegraphics

    Lcegraphics Member

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    You must have the DBM200? The Black hard rollers are not rubber. They are Ebonite which slips on some slick surfaced stocks. These rollers can be replaced with Rubber rollers like the new Duplo systems.
    Apply the tesa tape on the front fold roller only, not both fold rollers. The front fold roller is the one that contacts the front of the cover.
    Joe
     
  5. jpfulton

    jpfulton Member

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    No, it's called the "Standard Duplo 12/24"
     
  6. jpfulton

    jpfulton Member

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    Here are pictures of the model name and the fold rollers...


    20140924_092113.jpg

    fixed_roller_pic.jpg
     
  7. jpfulton

    jpfulton Member

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  8. Lcegraphics

    Lcegraphics Member

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    Duplo 12/24

    I see the folder. You have the original DC48F. It had hard plastic rollers. Those rollers look like (backolite) they are a hard plastic. Similar to Ebonite.
    They can be replaced with rubber if the tesa tape does not help.
     
  9. jpfulton

    jpfulton Member

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    Okay and as far as the tesa tape.. Which 'model' is it specifically? I see one called Tesa 4863 PV3 also known as "Printer's Friend". Assuming that's it. I can't seem to find a good source online and it appears to be very expensive. Do you know where to get it and what I should expect to pay?
     
  10. Lcegraphics

    Lcegraphics Member

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    Duplo

    Order it from Update Bindery Services
    Also please call me if you need further assistance. I am not a typist.
    Just trying to help
    Joe
    1-352-799-8393
     
  11. jpfulton

    jpfulton Member

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    Thanks Joe
     
  12. pressman1

    pressman1 Member

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    Did you try cleaning your rollers with alcohol, I had the same problem, when rollers
     
  13. pressman1

    pressman1 Member

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    when rollers are glazed up they will slip
     
  14. jpfulton

    jpfulton Member

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    Yes actually which solves the problem for about 200 books then it begins again... according to the operator. To me that is somewhat satisfactory but I also understand that when you're running an average of maybe 500 a day and sometimes 6,000 in a single day (which is what happened recently that really sparked the desire for a solution).

    Not sure exactly if glazed up applies to our situation -- sounds like maybe you're referring to rollers on a press?

    I talked to Tesa and they are sending us a sample of the tape so we can try before paying $80 for 27.5 yards of tape of which we'll probably only end up needing about 1 yard.
     
  15. pressman1

    pressman1 Member

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    glazing is just when foreign material builds up on the roller, varnish, toner, etc.
    I mostly had problems when I folded press sheets that were coated with varnish.Toner from digital machines make sheets very slippery too. Sounds like that tape is the answer for you, good to know in case I run across that problem.
     
  16. jpfulton

    jpfulton Member

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    Yeah, fingers crossed. I'll come back and report my findings.
     

  17. jpfulton

    jpfulton Member

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    We tried some "tesa 4863 Printer's Friend" (link) and it has solved the problem. Our operator is saying that he is no longer having any problems with that part of the machine at all. Thank you LCE for the suggestion

    One of the only other problems we are still experiencing on large-ish (64 page+) booklets that have a lot of toner coverage on the covers (65lb cover), is when they get to the final delivery unit -- the conveyor with the weighted wheel -- they can get stuck trying to go under the wheel. We tried putting the tesa tape on the wheel but that hasn't helped. I almost wonder if putting tape on the conveyor belts might help or if we need less weight in the wheels. Anybody have any ideas on this?
     
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