Materials for the manufacture of common notebooks. How notebooks are made

Making simple notebooks

Question number 1. List the main steps in the manufacture of simple notebooks. Sheet colliding technology and factors affecting colliding accuracy and performance.

Making simple notebooks

Block diagram of TBPP editions in the cover

Block diagram of TBPP hardcover editions

Sheet processing nomenclature printed matter into book editions, which includes finishing and binding processes, contains more than 70 different operations necessary to turn prints into a packaging unit for the main products of book printing houses. Depending on the volume, design, level of artistic and printing design, requirements for strength and durability, the number and composition of operations can vary significantly, but all of them can be grouped into seven or eight complexes of sequential operations, which at a certain stage, in the presence of source materials and touched semi-finished products, can be performed independently. At large printing enterprises, in order to improve the organization of production, these complexes are separated into workshops or departments of a large workshop, and in the textbook they are grouped into sections, which contributes to the assimilation of the content of the TBPP discipline and the very concept of "technology": this is not only a set of processing methods, changes in properties and forms of material or semi-finished product in the production process, but also a strict list and sequence of operations, withdrawal and rearrangement, which can lead to the loss of important consumer properties of the product, and in the binding processes - book publication.

Completing a book block not from separate sheets, but from notebooks is not only a tribute to the old technology of binding handwritten and early printed books, but also a technological necessity. The production of books assembled from notebooks, and not from separate sheets (shares), makes it possible to reduce labor intensity and the likelihood of errors when assembling a block, to choose a method of its fastening and processing, ensuring good openness, high strength and durability of the book. It is technologically and economically feasible to make book blocks from 32-, 16- and 8-page so-called simple notebooks, obtained respectively with four-, three- and two-fold perpendicular symmetrical folding, as this ensures minimal time and labor costs in manufacturing operations blocks, high sewing bond strength and good quality mechanical processing of the spine, full use of the technological capabilities of printing machines and minimal costs in prepress processes, allows you to get the maximum strength and durability of books.

The production of simple book notebooks from prints obtained on sheet-fed printing machines includes the operations of colliding, trimming, and cutting sheets into parts, folding, pressing and binding notebooks and storing them until all structural parts of the book block are ready for further processing.

Sheet collision

Alignment of the edges of various sheet materials and prints on two adjacent ends of the foot is performed in order to increase the reliability of the feeders of printing, finishing and folding machines and the quality of products of single-knife paper-cutting machines. It is necessary in cases where the shift of sheets in a stack due to inaccurate operation of the take-up device of sheet-cutting and sheet-fed printing machines or careless transportation exceeds the tolerances for the amount of shift of sheets for the smooth operation of feeders, for the format and accuracy of cutting sheet materials and products. Unprinted paper, prints and various sheet binding materials are collided before printing, finishing, cutting and folding.

Push technology

Sheets are collided manually, on colliding semi-automatic machines and on automated integrated systems, which include a colliding machine. Pushing sheets manually is performed on a horizontal table with a flat and smooth surface, the width of which is somewhat greater than the diagonal of the sheets being processed. With manual pushing, the worker transfers a small (convenient to work) stack of sheets from the pallet to the pushing table, forms an “air lubricant” between the sheets of the stack with special techniques, spreads the stack with a “ladder”, aligns it with soft blows on the table surface alternately along the edges of the right angle, after pushing the air between the sheets with the palm of his hand and placing the stack on the feeder table, cutting machine, or other pallet. On a collided foot, the correct edges are marked with a colored pencil or, if the paper is intended for printing covers and postcards, by cutting off the right corner up to 10 mm from its top. When sealing the front side of the sheet, the right angle is marked with a special mark - a narrow strip up to 3 square meters long. on the side of the sheet. The marks in the stack form a clearly visible stripe on the end face.

With manual pushing, the labor of the worker is heavy and unproductive: he lifts and lowers each stack of paper to the surface of the table from 2 to 6 times, processing up to 4 tons of paper per shift. In small and medium-sized printing enterprises, simple-designed and affordable collating machines are used for colliding. Such a machine has a massive base, a table with two low walls-stops, a sheet blowing system and an electric drive that ensures the vibration of the table during the collision. During operation, the table occupies an inclined position, and the sheets, due to air lubrication and their own gravity, are aligned against the side walls. The loading of the pusher machine should be done in small stacks, since with a large mass of the stack, the sheet blowing efficiency is significantly reduced, and the time for aligning the sheets along the side walls increases. Modern medium and large printing companies use automated complex systems that serve the processes of pushing, cutting and all related transfer operations.

After colliding, sheets of paper and prints should be counted and stacked in stacks of 500 copies on pallets in stacks that should not exceed 1.6 m in height. Stacks should be separated from each other by strips of colored paper to assess the amount of work performed and the amount of paper available or semi-finished products.

Paper and semi-finished products after colliding are evaluated by a single quality indicator - colliding accuracy. The sheets in the stack must be exactly aligned, with a tolerance of 3 mm for paper and 4 mm for binding cloth. The accuracy of the collision is determined visually when the foot is "pumped" along the correct edges.

Factors affecting colliding accuracy and performance

The accuracy and performance of manual and machine pushing of sheets depends on the size, surface density, bulk density, smoothness and moisture content of the paper, as well as on the average value of the initial offset of the sheets and the condition of their edges.

Sheets of large format are less convenient to work with and, other things being equal, have a large mass, therefore, a stack of paper with a smaller number of sheets is taken for pushing than with medium and small format. The colliding performance is reduced by 17-20%. Paper with a high surface density, other things being equal, has a higher mass, thickness and stiffness, which has a twofold effect on the complexity of the operation: on the one hand, it is necessary to push stacks of paper with a smaller number of sheets, but, on the other hand, thick and rigid sheets of paper are relatively edges are easily aligned. For these reasons, for every 20% increase in paper basis weight, the jogging performance of paper over 90 g/m2 decreases by about 5%. Colliding sheets of thin types of paper with a low surface density is difficult due to their low rigidity. When aligning sheets on a hard surface of a table or the walls of a pushing machine, the probability of crushing their edges increases significantly. With this in mind, the production rates per collision of paper with a basis weight below 55 g/m2 are reduced by about 17%. Thin types of paper with a low surface density (for example, cigarette paper with a surface density of 16 g / m2) cannot be collided at all; they are leveled by pinning each sheet onto needles.

Sheets of calendered and coated paper with high smoothness slide well over each other and collide easily. High-calendered paper with a smoothness of more than 300 s and coated paper before trimming and cutting can not be pushed at all, but aligned by pushing it to the feeder and stop when laying the stack on the table of a single-knife paper-cutting machine.

The increased humidity of the paper makes it difficult to collide, as this reduces its rigidity and increases the coefficient of friction. At low (less than 5%) humidity, paper is easily electrified by close contact and friction of the sheets. The accumulation of charges during electrification leads to sticking of the sheets, which makes it difficult to perform basic colliding operations. The optimal moisture content of paper for this technological process, equal to 7-8%, can be achieved at normal relative humidity in the workshop (60 ± 5)% and after acclimatization of the paper for a day.

Large initial shift of sheets, wavy, wrinkled and damaged sheet edges make it difficult to collide. At the same time, when loading flat pile feeders of printing, finishing and folding machines, collisions may not be performed if the initial sheet shift does not exceed 3 mm. When loading round pile feeders of folding machines, collisions can be avoided even with a larger (up to 10 mm) offset of the edges of the sheets.

Question number 2. To characterize and describe the technology of manual picking and picking processes.

Making book blocks

The production of book blocks means two operations - the assembly of blocks and their fastening, but these are the key, most important operations in the technology of stitching and binding processes, since the quality of their execution to the highest degree determines the main consumer properties of book-type publications: ease of use and required durability.

Completing blocks with a tab (notebook to notebook) is used in the manufacture of small-volume book publications - “thin” magazines for various reading purposes, books for preschool and younger children school age, technological instructions for individual operations, various documents (membership cards, record books, etc.) and white goods. The volume of such publications and products usually does not exceed 128 pages, and the block thickness is 6.5 mm. The thickness of the book block when assembling with an inlay is limited because the width of the outer shares of the paper sheet after cutting the block or publishing when bending the inner shares along the radius R (Fig. 5.1) decreases by an amount l proportional to the thickness of the block.

In industrial enterprises, if possible, the production of complex notebooks should be avoided, since after folding, individual order notebooks must be separated and additionally processed. This requires prohibitively large logistics costs and special coordination in order fulfillment planning. Correct product design contributes to the elimination of difficulties. Printing products are given such a look that the need for preparatory work no longer arises. For example,

 do not use the end notebooks of a block of 2 or 4 pages;

 Instead of gluing illustrations in notebooks, illustration sheets are planned in a notebook block and images are applied to them.

Ability to minimize excessive technical costs for preparation period consists in integrating the initial stages of the process into the preliminary (folding) or final stages of the process (for example, collation).

This is often done when sticking maps on sheets of magazines and when gluing endpapers for a notebook block.

Processing of notebooks at a separate stage of the process is carried out by machines for gluing sheets or notebooks (Fig. 4). Machines able:

 stick separate sheets or folded sheets to the main notebooks;

 insert or paste individual sheets or folded sheets in the middle of the main notebooks;

 fasten separate sheets or folded sheets on the main notebooks (two or more strips of glue);

 to apply or fix illustrations of a smaller format on the main notebooks or in the middle of the main notebooks.

Glueing the flyleaf

Endpapers are obligatory elements of hardcover constructions, since by means of a flyleaf, a notebook block is fastened with a cover on the first and last sheets. Endpapers are usually four-page notebooks made of paper that is especially resistant to bending, which are glued with an adhesive strip to the spine inner margin of the notebook block before the first sheet and after the last one. When connecting the block and the cover, the outer sheet of the flyleaf (mirror) is glued over the entire surface to the side of the cover).

Combined device for gluing sheets or notebooks (Einklebeautomat VEA 520, Hunkeler)

A quick break at the junction leads to the rejection of the endpaper and gluing the first and last sheets notebook block with lid.

Bookbinding shops use special bookend designs to make the opening hinges especially resistant to wear.

The integration of gluing the flyleaf with the stage of manufacturing the notebook block is implemented in three versions:

 by using the endpaper-adhesive module in binding production lines (Fig. 6) with adhesive bonding;

 by using a module for gluing endpapers in production lines for post-printing processing of books with sewing binding;

 as a “dust jacket replacement” in seamless binding devices (Fig. 7).

The placement of the endpaper gluing section in the production lines for seamless binding is carried out between the collating machine and the machine for seamless binding (Fig. 6).

In one of the frequently used technical implementations, the endpapers arrive after they are divided into guides, which set the endpapers 3–5 mm above the surface of the spine of the notebook block. While moving, they are smeared with glue on the adhesive strip applicator and glued to the aligned outer sheets of the notebook block. In a seamless binder, the spine folds of the notebook block are removed, while the bookend folds are retained. The roots are glued, then they are edged. The edging strip provides additional strength to the endpaper.

A rational option is to stick the endpapers with the help of feeder covers in machines for seamless binding. To do this, endpapers are glued to the edging strip. This structural element of the notebook is fed by means of a feeder of covers to the glued spine of the block (Fig. 7) and glued to it.

Pasting cards into magazines (brochures, stitched saddle) is carried out in collating and sewing machines.

Rice. 5. Endpapers in the manufacture of industrial hardcovers

Rice. 6. Device for gluing endpaper on production lines

Rice. 7. Glued bookend

In this case, the card gluing device is either installed instead of the feeders of the notebooks in insertion machines (Muller Martini) or placed between the feeders.

Quality problems when gluing bookends

In the process of gluing endpapers, there are three types of defects:

 block and flyleaf are connected with too wide and/or non-uniform adhesive strip. This disadvantage appears either due to a too thick layer of glue, or due to the use of low-absorbent papers (for example, coated ones), so that the glue is squeezed out at the joints during crimping;

 The adhesive surface breaks off during post-processing of the book block or when using the final product. The reason for this shortcoming is the use of unsuitable glue for gluing the endpapers. In particular, this occurs when processing sheets with text that is printed over the entire surface of the sheet up to the spine margin, where the surface is not sufficiently wetted with glue. The problem can be reduced by using better flowable adhesives. However, it is best not to seal the surfaces to be bonded;

 the endpaper is glued with a large indent from the spine of the notebook. As a result, so-called "stresses" appear in the notebook, which, when using the notebook, can lead to premature destruction.

The problem is illustrated in the diagram (Fig. 8). If the flyleaf is too far away from the spine of the block, as shown in the middle figure, the position of the flyleaf opening hinge and the lid fold will no longer match. Therefore, when the lid is opened (bottom figure), the first sheets of the notebook block around the center of rotation - the fold between the lid and the lagging - are stretched, as a result of which increased stresses are formed in the bond. These increased loads destroy the adhesive joints, which under normal conditions have sufficient strength.

Making simple notebooks

Block diagram of TBPP editions in the cover

Block diagram of TBPP hardcover editions

The nomenclature of processing sheet printed products into book publications, including finishing and binding processes, contains more than 70 different operations necessary to turn prints into a packaging unit for the main products of book printing houses. Depending on the volume, design, level of artistic and printing design, requirements for strength and durability, the number and composition of operations can vary significantly, but all of them can be grouped into seven or eight complexes of sequential operations, which at a certain stage, in the presence of source materials and touched semi-finished products, can be performed independently. At large printing enterprises, in order to improve the organization of production, these complexes are separated into workshops or departments of a large workshop, and in the textbook they are grouped into sections, which contributes to the assimilation of the content of the TBPP discipline and the very concept of "technology": this is not only a set of processing methods, changes in properties and forms of material or semi-finished product in the production process, but also a strict list and sequence of operations, withdrawal and rearrangement, which can lead to the loss of important consumer properties of the product, and in the binding processes - book publication.

Completing a book block not from separate sheets, but from notebooks is not only a tribute to the old technology of binding handwritten and early printed books, but also a technological necessity. The production of books assembled from notebooks, and not from separate sheets (shares), makes it possible to reduce labor intensity and the likelihood of errors when assembling a block, to choose a method of its fastening and processing, ensuring good openness, high strength and durability of the book. It is technologically and economically feasible to make book blocks from 32-, 16- and 8-page so-called simple notebooks, obtained respectively with four-, three- and two-fold perpendicular symmetrical folding, as this ensures minimal time and labor costs in manufacturing operations blocks, high strength of sewing binding and good quality of mechanical processing of the spine, full use of the technological capabilities of printing machines and minimal costs in prepress processes, allows you to get the maximum strength and durability of books.

Sheet collision

Push technology

Factors affecting colliding accuracy and performance

Question number 2. To characterize and describe the technology of manual picking and picking processes.

Making book blocks

Completing blocks with a tab (notebook to notebook) is used in the manufacture of small-volume book publications - “thin” magazines for various reading purposes, books for children of preschool and primary school age, technological instructions for individual operations, various documents (membership cards, record books, etc. .) and white goods. The volume of such publications and products usually does not exceed 128 pages, and the block thickness is 6.5 mm. The thickness of the book block when assembling with a tab is limited because the width of the outer shares of the paper sheet after cutting the block or publishing when bending the inner shares along the radius R (Fig. 5.1) decreases by an amount l proportional to the thickness of the block:

In the finished product, this leads to a significant decrease in the margins on the inner sheets, since even with a snug fit in notebooks and precise folding, with a block thickness of 5-6.5 mm, the leading edges of the sheet shares and typesetting strips at the outer sheets of notebooks are shifted by 4- 5 mm, which, of course, reduces the quality level of book publications, but it is quite acceptable in the production of white goods - weeklies, general notebooks, etc.

Book block assembly technology

The picking of blocks with an insert and a selection is done manually, on insert-sewing machines, on insert-sewing-cutting units and on pick-up machines, moreover, in the manufacture of publications in a cover, picking with an insert is always combined with covering with a cover.

Manual picking with a tab

At small printing enterprises, with a shift load of the workshop for the operation of completing blocks of up to 18-20 thousand three-fold notebooks, one worker can complete the assembly with an inlay with covering the blocks with a cover. Manual picking of book blocks with a tab is carried out on a horizontal table after a preliminary check of the stacks of notebooks according to the norm and signatures by pouring them “on a fan”. The stacks of notebooks are placed on the right side of the table with the initial pages with the signature down, the top edges towards themselves and the spines to the left (Fig. 5.2).

Rice. 5.2. The layout of notebooks and blocks for manual assembly of blocks with an inlay: B - a stack of internal notebooks; H - foot of outer notebooks; O - stack of covers; B - stack of completed blocks

The stack of inner notebooks is placed first on the right, and the stack of outer notebooks is placed last on the left. To the left of the stack of outer notebooks, a stack of covers is placed. For the convenience of work, the stacks of notebooks and covers are made of different heights so that each foot on the left is 1-1.5 cm lower than the right. The height of the right foot should not exceed 20 cm, otherwise it may crumble with careless movement. A stack of folded covers is laid in expanded form with the folds upwards and the upper edges towards themselves, since in the folded form it is impossible to lay the covers in a relatively high stack and it is difficult to separate them one by one during the folding process.

When working, the stitcher with his right hand separates the upper notebook of the extreme right foot and at the same time with his left hand opens the upper notebook of the adjacent foot located on the left, after which he pushes the inner notebook of the block into the outer one. Then the movements of the hands are repeated: with the right hand, part of the completed block is pushed into the next notebook of the third foot opened with the left hand, etc., and the entire block is pushed into the cover opened by the left hand. The completed and covered block is placed on the left edge of the table. When the height of the stack of completed blocks reaches a value convenient for further processing, it is carefully pushed first along the upper edge, and then on the spine and placed on the adjacent working table of the wire sewing machine or in trucks to be sent to subsequent operations or to the warehouse of semi-finished products.

In the manufacture of publications in the binding cover, the technology for completing blocks with an inlay is similar, but the process of completing the assembly itself ends with inserting parts of the blocks into outer notebooks with endpapers glued on both sides and edged spines.

Manual picking

Manual picking of book blocks with a selection with a small number of notebooks in blocks, as in the case of picking with an inlay, is performed on a horizontal table. Before laying on the table, the worker controls the quality of incoming semi-finished products, rejecting soiled and damaged notebooks; on the spines or on the upper edges of the stack of the last notebooks of the block, a mark is necessarily applied with a colored pencil to facilitate the separation of the completed blocks before they are fastened together. This mark can also be the mark of the performer, if two or more workers perform the picking.

If there are no more than 8 notebooks in the block, then the stacks of notebooks are placed on the table in pairs, on equal distance from the performer's workplace, with the radicular folds to the right and the upper edges towards you, in the order indicated in fig. 5.3. The assembly of blocks begins with the last notebook, laying it with your right hand on the table in front of you, after which the penultimate notebook is placed on it with your left hand. Further, the picking process is repeated until the stack of assembled blocks reaches a height convenient for further processing.

Rice. 5.3. Scheme of laying stacks of notebooks when completing with a selection of small blocks: 1-8 - stacks of notebooks; B - stack of completed blocks

If the number of notebooks in the publications is more than 8, then a stand 10 cm high is installed on the desktop so that the stacks of notebooks can be stacked in two rows at different heights. In the first row, farthest from the worker, stacks of notebooks of the first half of the block are placed on a stand, placing them from left to right. In the second, near, row, stacks of notebooks of the second half of the block are laid from right to left. The assembly of blocks begins with the last notebook, placing them on the palm of the left hand or on a cardboard blank of the appropriate format and moving along the table from left to right and right to left. At one time, the worker picks up several blocks with a foot of such a height that is convenient for him to work.

If the number of notebooks in book publications is more than 20, then it is advisable to make the desktop U-shaped. In this case, the worker can perform picking while sitting on a screw chair. With the so-called tetradless technology, when book blocks can consist of several dozen sheets of A4 or A5 formats, a two- or three-tiered shelf with cells is installed on the desktop, in which several hundred prints can be placed.

After picking the foot, it is pushed along the upper end and onto the spine, the correctness of the picking is controlled by spine marks, and then it is placed on the adjacent table of the machine for sewing or seamless fastening of blocks. At medium and large enterprises, the completed blocks are stacked in piles up to 30 cm high in trucks with folding shelves or on the shelf of an overhead conveyor carriage.

Question No. 3 Factors affecting the quality of blocks in the process of gluing, drying and crimping the spine

The quality indicators of block spine processing depend on the method and modes of gluing, drying and crimping the spine and technological factors - paper quality indicators and the volume of block notebooks.

Ways and modes of gluing the spine. According to MGUP, the variant with gluing and drying the spine in a clamped state, carried out on modern gluing and drying machines, is technologically the most advanced, as it provides maximum strength for gluing notebooks at high values of compaction coefficients and block shear resistance.

Glue consumption. If the block-gluing device ensures the application of a thin layer of glue of high concentration and any viscosity with the penetration of glue between the thickenings of the spine folds of adjacent notebooks, then the strength of gluing notebooks increases with an increase in glue consumption up to 0.6 kg / m2 for all types of paper (Fig. 6.2, a) . A threefold increase in glue consumption provides an approximately 1.5-fold increase in the gluing strength of notebooks made of non-adhesive types of paper and 1.6-2.5-fold for notebooks made of glued offset paper, while the absolute increase in gluing strength is up to 0.5 and 0, respectively. .2 daN/cm (kgf/cm).

Rice. 6.2. Dependence of the gluing strength of notebooks of blocks sealed with PVAD: a - on the consumption of glue; b - on the concentration of glue; 1 - letterpress paper No. 3; 2 - letterpress No. 2; 3 - for letterpress No. 1; 4 - offset No. 2; 5 - offset No. 1

glue concentration. An increase in the concentration of glue at a constant consumption (Fig. 6.2, b) gives a much greater effect: a twofold increase in concentration provides an increase in the strength of gluing notebooks from non-glued types of letterpress paper by 1.5-2.5 times (by 0.5-0 .6 daN/cm) and 3.0-4.5 times (approximately 0.4 daN/cm) for bonded offset paper. The use of concentrated glue at a constant dry matter consumption provides greater strength for gluing notebooks, better conditions for drying the spine, and saves glue when processing blocks of non-glued types of paper, if the adhesive consumption rate is set from the requirement of the necessary strength for gluing notebooks in accordance with the service life of the publication.

According to MGUP, when sealing the spine of blocks consisting of 32-page notebooks with undiluted 50% glue in compliance with the dry matter consumption rate, during the drying of the spine, it is necessary to remove no more than 30% of the moisture introduced with the glue. The rest of the moisture is filtered into the paper and remains in the adhesive film without interfering with subsequent operations. Simple calculations show that when using diluted adhesives containing 33% solids, in accordance with the recommendations of technological instructions and material consumption rates, 4 times the mass of moisture must be removed during drying in order to obtain the same moisture content.

Spine drying mode. With intensive drying methods, as the glue dehydrates, the gluing strength of the block notebooks increases, reaches a maximum with the loss of about 60% of moisture introduced with 33% concentration glue, after which it decreases. The gluing strength of notebooks at optimal moisture content increases with the use of severe modes of radiation-convective drying (with an increase in the power and temperature of the emitter, a decrease in the distance to the emitter - curve 1 in Fig. 6.3), which, apparently, contributes to the fusion of polyvinyl acetate particles, the formation of a monolithic film, diffusion polymer to paper.

Rice. 6.3. Dependence of the gluing strength of notebooks of blocks on the amount of moisture removed during drying with quartz infrared lamps: 1 - when gluing the spine with 50% PVAD; 2 - when gluing 33% PVAD

Spine crimping modes. When gluing and drying the roots of blocks in a clamped state, the compression modes are the pressure and the amount of exit of the roots from the clamps of the conveyor of the gluing dryer.

With an increase in the release of the roots of the blocks from the clamps and the pressure of crimping, the roots of the notebooks of the block diverge fan-shaped, which allows the glue to penetrate to a greater depth between the folds. At the same time, the gluing strength of notebooks of book blocks first increases (for various types of paper by 20-30%), reaches a certain maximum, and then decreases (Fig. 6.4, a and 6.5, a). With an increase in the exit of the roots from the clamps, the compaction coefficient of the blocks decreases (Fig. 6.4, b), and the shear resistance coefficient increases slightly; an increase in crimping pressure increases the compaction coefficient (Fig. 6.4, b), but reduces the shear resistance coefficient of the spine. The optimal value should be considered to be the value of the exit of the roots from the clamps, equal to 6-8 mm, and the crimping pressure of the order of 1-3 MPa, depending on the type of finish and volumetric weight of the paper, the volume of notebooks and the thickness of the block. With these values of the crimping parameters, the maximum bonding strength of notebooks and sufficiently high values of the coefficients of compaction and block shear resistance are ensured, which ensures high quality of semi-finished products at subsequent operations of machining the spine of book blocks.

Rice. 6.4. Dependence of the gluing strength of notebooks (a) and the coefficient of compaction of blocks (b) on the amount of spine exit from the clamps for blocks made of letterpress paper: 1 - No. 1, PVAD 33%; 2 - No. 1, PVAD 50%; 3 - No. 3, PVAD 50%

During the step-by-step processing of blocks, one- or two-time crimping of the spine is performed on block crimping machines of the BPB-270 type at a pressure of about 3-4 MPa (30-40 kgf / cm2).

Crimping the spine of the blocks after drying increases the coefficient of compaction, lowers the coefficient of resistance of the block to shear and does not affect the strength of gluing the notebooks of the blocks.

Rice. 6.5. Dependence of the gluing strength of notebooks (a) and the coefficient of compaction of blocks (b) on the pressure of the clamps for blocks of letterpress paper: 1 - No. 1, 33% PVAD; 2 - No. 1, 50% PVAD; 3 - No. 3, 50% PVAD; 4 - No. 3, 33% PVAD

Sizing, composition and volume weight of paper. Glued types of paper are worse wetted by PVAD, give a lower strength of the adhesive seam, therefore, the strength of gluing notebooks of blocks made of glued offset paper (see curves 4 and 5 in Fig. 6.2), ceteris paribus, is 2-4.5 times lower than that of non-glued types of letterpress paper (see curves 1-3 in Fig. 6.2). Paper containing wood pulp (No. 2 and No. 3), compared to paper made only from cellulose (No. 1), as a rule, has a lower bulk density, greater porosity, is better wetted by glue and therefore provides a significantly greater bonding strength.

The volume of block notebooks. If the block is made of 32-page notebooks, then compared to 16-page notebooks with the same glue consumption, the gluing strength of the notebooks is approximately 10-15% higher due to the increase in the gluing width between the spine folds of adjacent notebooks.

paper moisture. The coefficient of compaction of the blocks and the strength of the adhesive seam for paper with low moisture content increase when using PVAD diluted to 40-45% of the dry matter content, but the strength of the adhesive film is significantly reduced. Paper with low moisture at the first stage of formation of the adhesive seam very intensively absorbs the moisture of the glue, which worsens the wettability of the paper with glue and the strength of the adhesive seam. If blocks with low (less than 5%) humidity are received for gluing the spine, then the concentration of glue should be slightly reduced. The strength of the gluing of notebooks can be increased if the spines of the blocks are smeared twice with glue: successively diluted and concentrated PVAD.

Bibliography

Reference technologist-polygraphist. Part 6. Stitching and binding processes / Comp. L.G. Granskaya, O.B. Kuptsova. - M.: Book, 1985.

Technology after printing processes. D.V. Vorobyov 2000.

For the preparation of this work, materials from the site http://www.yuro.ru were used.

Paper is one of the most important inventions of man, allowing high-quality exchange of information. It is used in various sectors of the national economy.

Particular attention should be paid to school notebooks, which are a necessary element in the education of each person. You can find out how to choose the right product on the website www.masteroffice.com.ua/tetradi-shkolnye/.

Receipt of paper

Paper is the main component of any notebook. Therefore, the production of such products begins precisely with the receipt of high-quality blanks. This process can be described in the following sequential steps:

shredding wood. For such purposes, only a tree without bark is used. Therefore, it is previously removed from the trunks. After that, special mechanisms grind the material;
cooking. Notebook paper is of high quality. To obtain such cellulose, the tree is exposed to various chemical substances. Before this, the crushed material is carefully sorted and sorted. After that, the pulp is cooked in various acids;
cooking. When all the components are prepared, several types of glue and various resins are added to them. To give paper White color, kaolin is also added to the solution. After that, the mixture is fed to special machines, where it is dried and pressed. Formation of paper is carried out by special rolling machines.

Manufacturing technology

Notebooks are a small semblance of a book, only with a small number of sheets. There are many varieties of such products on the market today. But all of it is made using approximately the same technology. This process can be broken down into several steps:

seal. This stage involves the use of special printing machines. Please note that it is important here not only to print the inner sheets, but also to pre-design the cover. Therefore, this step is given great attention. All operations are performed separately on large sheets. After printing, they are cut into certain blanks;
fastening. This process can be carried out according to various technologies. by the most simple option is the fastening of sheets with paper clips. The machine simply punches through a stack of paper and bends the wire. But today very often rough notebooks are stitched with original springs.

Making notebooks is a complex and Long procces requiring special equipment and skills to work with it.

Question number 1. List the main steps in the manufacture of simple notebooks. Sheet colliding technology and factors affecting colliding accuracy and performance.

Making simple notebooks

Block diagram of TBPP editions in the cover

Block diagram of TBPP hardcover editions

Completing a book block not from separate sheets, but from notebooks is not only a tribute to the old technology of binding handwritten and early printed books, but also a technological necessity. The production of books assembled from notebooks, and not from separate sheets (shares), makes it possible to reduce labor intensity and the likelihood of errors when assembling a block, to choose a method of its fastening and processing, ensuring good openness, high strength and durability of the book. It is technologically and economically feasible to make book blocks from 32-, 16- and 8-page so-called simple notebooks, obtained respectively with four-, three- and two-fold perpendicular symmetrical folding, as this ensures minimal time and labor costs in manufacturing operations blocks, high strength of sewing binding and good quality of mechanical processing of the spine, full use of the technological capabilities of printing machines and minimal costs in prepress processes, allows you to get the maximum strength and durability of books.

Sheet collision

Push technology

Factors affecting colliding accuracy and performance

The increased humidity of the paper makes it difficult to collide, as this reduces its rigidity and increases the coefficient of friction. At low (less than 5%) humidity, paper is easily electrified by close contact and friction of the sheets. The accumulation of charges during electrification leads to sticking of the sheets, which makes it difficult to perform basic colliding operations. Optimal for this technological process paper humidity equal to 7-8% can be achieved at normal relative air humidity in the shop (60 ± 5)% and after paper acclimatization during the day.

Question number 2. To characterize and describe the technology of manual picking and picking processes.

Making book blocks

Book block assembly technology

Manual picking with a tab

Manual picking

If there are no more than 8 notebooks in the block, then the stacks of notebooks are placed on the table in pairs, at an equal distance from the performer's workplace, with the spine folds to the right and the upper edges towards themselves, in the order indicated in Fig. 5.3. The assembly of blocks begins with the last notebook, laying it with your right hand on the table in front of you, after which the penultimate notebook is placed on it with your left hand. Further, the picking process is repeated until the stack of assembled blocks reaches a height convenient for further processing.

Rice. 5.3. Scheme of laying stacks of notebooks when completing with a selection of small blocks: 1-8 - stacks of notebooks; B - stack of completed blocks

Question No. 3 Factors affecting the quality of blocks in the process of gluing, drying and crimping the spine

During the step-by-step processing of blocks, one- or two-time crimping of the spine is performed on block crimping machines of the BPB-270 type at a pressure of about 3-4 MPa (30-40 kgf / cm2).