Binding Solutions, LLC

Many of the savings mentioned in our lead article were realized at Banta Corporation Information Services Group, Spanish Fork, UT when it switched to COOL-BIND. The printer of software user manuals was the first bindery to invest in the low-temperature hot melt.
Selecting this advanced adhesive is one of several steps by which Banta produces high quality publications in minimal time.
As other steps, Banta operates with advanced equipment such as high-speed printers with up to five colors, fast drying inks and aqueous coaters. Comprehensive quality control also is a way of life here, since achieving ISO certification is critical for customers based in Europe and large American corporations. Banta's quality focus extends to selection of paper, inks and binding adhesives, and in well-qualified and highly-trained employees.
COOL-BIND Contributions
COOL-BIND contributes to Banta's quality and productivity by conferring on books excellent page pulls and pages that don't wrinkle. The adhesive allows more books to be produced per hour while fostering worker comfort.
As production speed rises, former Bindery Manager Keith Burgess says, "This fast-setting adhesive requires less drying time before trimming. With a 100°F lower starting temperature than conventional hot melt adhesives, the spine glue cools much faster."
The higher line speed made possible by COOL-BIND can easily produce an extra 1 million books per year for a large bindery like this one. Profitability improves accordingly.
Since the adhesive has been largely cured before trimming, the trimmer knives don't smear as happens with standard EVA's. No trimmer jams or lost production time occur from smearing at the trimmer. Trimming is clean, books look clean, paper doesn't tack together.
Improves Quality
As quality improves, "Page pull readings are consistently high," says Burgess. Banta ISG confirms page pulls by inspecting the bookblocks every 10 minutes and performing a pull test on its Moffett Precision Products Adhesive Book Bound Tester every 20 to 25 minutes.
Since switching to the new low-temperature hot melt, Banta's bindery operators no longer worry about wrinkling when binding cross grain. The lower temperature drives less moisture from the paper, so there's less chance for wrinkling when moisture in the paper tries to balance throughout the sheet. By contrast, a conventional 350°F hot melt does not allow the expanding paper to move, since the hot melt has already solidified. The only expansion that can take place is in the fibers, causing a wrinkle.
Because of its low temperature, the new adhesive keeps its light color hour after hour, with no darkening. No charring takes place, which would impair production equipment and weaken final adhesion of pages. Operators at Banta ISG are thankful for the improved working conditions from the new low temperature hot melt. There is little odor emitted compared to a pungent odor previously. The low temperature makes working with COOL-BIND safe, but Banta still stresses wearing gloves and goggles.
Cost Savings
For other production cost savings, Burgess says, "The lower heat requirement means we save on electricity. We save additional money by not having to change heating elements so often in the glue pot and premelters."
Another reason Banta switched to this low-temperature hot melt was the adhesive's ability to perform for a range of paper stocks. Banta mostly works with 40-pound through 60-pound uncoated stock. It also uses some 45-pound through 70-pound matte sheets and some 70-pound and 80-pound gloss stock. For cover stock, Banta runs a lot of 10-point, board-grade, coated-one-side stock.
For side glue, Banta ISG uses National's UNI-FLEX™ 34-1211 adhesive. "We find that the UNI-FLEX adhesive is very forgiving and an excellent product," Burgess says. For off-line tape and rep covers, Banta ISG uses National's RESYN™ 33-1556 white adhesive.
Burgess also notes that these high performance adhesives are backed by exceptional service from National's representative Gary Marshall.
Binding Solutions, LLC. Copyright 2015.