A hardcover system from Müller Martini/VBF: All work steps, from full-surface pressing to fitting of the cover, can be carried out here in a single pass.

Approximately 55% of all books in Germany are still sold at bookstores, according to Capital Market Group data. Other distributors are the publishers themselves, mail-order bookstores, book clubs, department stores and supermarkets. Mail-order now has a market share of eleven percent and, as a result of increased orders via the Internet, are characterized by the highest rate of growth. Its share grew by 25 percent from 2004 to 2005; that is a interesting trend. It is not only the sales channels that are in flux; there are also changes in the products, as well. For example, the hardcover share has increased, especially in fiction. While the hardcover revenue share for fiction was only 39 percent in 2003, it already reached 44 percent in 2005. This shift from paperback books to hardcover is due in part to the low-cost hardcover editions of the large newspaper and magazine houses, which show a stronger presence in 2004.

In addition to the low-price books, niche products and short runs continue to play a role in the everyday life of the bookbinder. The prices paid to bookbinders for large runs are dropping. They can earn a lot more with special forms and short runs. Those special forms include complex, processed books, such as CD booklets and full-flap books. The short runs include BoD products to an increasing degree, in addition to the circulations of regular published works, which have decreased in recent years. Individualized photo books are gaining popularity here, for example. The bookbinder needs the right means of production in order to create orders for niche products and short runs: machines that can handle the widest variety of demands with flexibility.

CD booklets produced on the VBF hardcover system.

New and Further Development for Efficient Book Productions
Müller Martini/VBF meets these demands with new and further development of its machines. Fast changeovers are essential to every profitable production. With the Commander operator control, the Tele-Commander console and the new Remote-Commander, Muller Martini/VBF offers the most modern tools for designing efficient production methods. The Remote-Commander permits the data contained in the Commander to be viewed and further processed at an external workstation.

In addition to the general automation of the machines and their thorough user-friendliness, VBF applies great care to the individual process steps. They are analyzed repeatedly and the machines are further developed accordingly. High-tech processes that deliver the highest quality and efficiency are the result. The Ventura book sewing machine, for example, is characterized by a patented thread loop formation process. The loops are formed with the help of air nozzles, which shortens job changeover time and thereby increases efficiency. Book blocks can be run without blank stitching with the Ventura - thanks to the thread sealing. In the case of thin products, this increases performance by up to a third. The Ventura’s variable opening principle opens all signatures with absolute reliability – regardless of the type of paper. Even in the case of two-up productions or signatures with double gate fold, it operates with extreme reliability.

For the efficient, automatic production of thread-sewn brochures and book blocks, Müller Martini can connect up to three Ventura book sewing machines to the VenturaConnect thread sewing system. An efficient solution with which the manufacturing costs for thread-sewn products are significantly lowered. The signatures are gathered, stacked and subsequently processed into thread-sewn book blocks – all in a single pass.

Flexibility in the Choice of Gluing Process
The Collibri now offers even greater flexibility when gluing-off, as now PUR glue can also be used. The PUR option can be retrofitted on existing machines. As an additional version, there is now also the Collibri for one-shot dispersion glue application. In the case of the machines for two-shot glue application, the exchangeable glue trolley allows different gluing processes to be used, depending on what is desired for the respective production. This makes the widest variety of gluing processes available to the bookbinder.  The wide gauze roll, among other things, provides for an uninterrupted run. No replacement of the reel is required when changing the book block thickness; a 984 ft (300 m) roll is sufficient for 6,000 blocks at a block thickness of ¾” (20 mm.)
In the downstream book block drying and pressing machine, the spine area is precisely pressed with uniform pressure and dried with infrared dryers. Any spine swelling is eliminated here permanently.

The Diamant Bookline Achieves the Highest Book Quality
The bookline contains all of the work steps of bookbinding, from rounding to back-gluing and casing-in to joint forming. In order to provide for all needs, Müller Martini/VBF offers the Diamant in two speed ratings. Whether at 30 or 60 cycles per minute, all quality-related processes are identical. The proven double nipping and exceptional, continuous joint forming and pressing processes are the most important guarantees for perfect book design. Books produced on the Diamant are therefore of exceptional quality. Whether they are works with gilt edges, gatefold books, books with plastic covers or standard hardcover books – the quality is always exceptional.

For efficient use, connected systems need buffers. The BLSD 650 D represents such a buffer, if required. When it is not needed for stacking, it can turn and buffer books in bypass mode. If required, this function can activate automatically.

Covers are positioned precisely and firmly with the Vesta book jacketing machine. The Vesta is also characterized by very short changeover times, thanks to its innovative technology and Amrys automatic adjustment system. Headbands and covers of gatefold books can also be folded in inline with the Vesta.

With the appropriate production systems from Muller Martini/VBF, bookbinders can produce books in the widest variety of designs at affordable prices, for a long time to come. Whether they are sold due to a librarian’s advise in the book shop or via mouse click on the Internet, that is the choice of the consumer, above all.