Automatic Gathering & Sewing Line UNIT

Smyth automatic gathering and sewing line mod. UNIT consists of a vertical gatherer mod. P12 and is connected in line with an automatic book sewing machine series 4D (FF-250 and FF-280).

This automated solution is designed for small and medium runs, and it is distinguished by the patented gatherer that gives the advantage of loading one or two signatures in each gatherer station, depending on their size. Thanks to this feature, the floor space required for this line is dramatically reduced and only one operator is needed to run the whole production system.

• Ideal solution to drastically reduce the production costs of the sewn book
• Exceptional compact design
• Automatic enabling of the gatherer stations for a drastic reduction of set-up times

FEATURES:

• Reduced set-up times - The simple loading of signatures on the gatherer stations automatically enables their use, drastically reducing the set-up times.
• Signatures doubling - In the same gatherer station, the operator can load signatures having size up to 640 mm or two signatures in sequential order, having head to tail size up to 320 mm. Therefore, for example, the gathering line composed of 9 stations transforms into a line having 18 stations. In this way it is possible to double the number of signatures to be collected, reducing the overall need for floor space and facilitating the loading/unloading operations that can be performed by only one operator.
• Hand feeding station - The UNIT line is equipped with a hand-feeding station to feed pre-gathered signatures. This station allows completing the book, if the number of the signatures is higher than the available gatherer stations.
• Easy restart - In the case of signature jam, the gatherer finger that transports the signature is automatically released. Once the jam has been removed, the finger automatically repositions itself, making the machine restart easier and faster.
• Operator interface - Programming and diagnostics are performed through OMRON PLC and new software designed by the in-house team of Smyth engineers. A color touch screen is positioned centrally on the book sewing machine and additional touch screens are provided on the gatherer – every 3 (6) stations-, to enable all machine functioning parameters to be checked, together with the setting of the main automatic machine adjustments.
• Smyth stacker “Easy Stack” - Smyth UNIT is equipped with a stacker that makes piles of sewn books delivered by the sewing machine in order to facilitate the unloading operations. Pile height is programmable up to 120 mm.

OPTIONAL

• Courier Device - conveys gathered signatures to the in-line sewing machine and to an additional off-line book sewing machine, doubling the production capacity of the whole system. This is possible thanks to the gatherer's high production capacity.
• Gathering sequence control - self-learning system performed by Omron Camera. This camera performs the gathering sequence control by reading bar codes, text and images. Thanks to continuous measurements, this system ensures the highest level of control by filtering data and info, preventing false alarms and unnecessary stops.
• Modular design -  the number of gathering stations can be increased even after the installation of the line. This is possible by adding single gathering modules composed of 3 stations (which turn into 6 stations when doubled).
• Signature bidirectional transport system - 2-way signature transport system allows the conventional use of the gatherer connected in line with the sewing machine, or its use in line with an existing perfect binder/stacker.