Computer-aided Binding System CABS4000V

CABS4000V
Computer-aided Binding System

Automated/Variable 9-Clamp
Perfect Binding System.

The space-efficient CABS4000V binder
combines high-performance automation,
simplicity of operation, superior productivity,
and absolute quality control for short,medium and longer run lengths.

CABS4000V Features
1. High productivity at 4,000 books per hour with in-line system from gathering to trimming.
2. Color touch screens provide easy, intuitive operation for fast, accurate changeovers and quick adjustments for production flexibility.
3. Equipped with interchangeable tank unit that allows binding with both EVA and PUR hotmelt.
4. Various book sizes can be bound in-line, from minimum size A6 to maximum size A4.
5. Off-line signature gathering is possible using the ST-600 stacker. Also, by installing the RU-600 misfeed unit the gatherer can operate non-stop.
6. Quality control image checking cameras, thickness detector, weight checker and other optional
quality control features.
7. The Horizon bindery management system (pXnet) can also be added, for further to increase in efficiency and effectiveness of the binding process. The pXnet is ready to receive JDF data.

2

System Gatherer
1. Combine up to 6 gathering units for a total of 36 stations.
2. Intuitive operation via intelligent touch screen control.
3. Image checking cameras (option IC2-MG600) detect sheetsthat have been improperly positioned or misprinted.
4. Used stations and settings of the detecting sensor can bememorized.
5. The ST-600 on/off-line stacker allows gathering to be performed off-line from the binder.
OptionBook block thickness detector (TD-600)

Operation section

Feeding section

For enhanced quality control, the book block thickness is measured so that
only good books proceed
to the next steps. Set-up isdone through the intuitive
touch screen.

Large color touch screens
are used on each unit for
efficient operation. Settings on a gatherer can bememorized in job memory.

Stable paper feeding isprovided. Each feed station is equipped with astatus indicator lamp.

OptionImage checker (IC2-MG600)

OptionBook block rejecting unit (RU-600)
RU-600 rejects any incorrectly collated
signatures so the whole system can run nonstop, for maximum productivity.
OptionImage checking camera checks the image on each feedcycle to prevent incorrect
signature or sheet feeding,for absolute document integrity. The captured imageis shown on each display
for visual confirmation.
OptionOn/Oﬀ-line stacker (ST-600)

Hand feed unit for MG-600H (HF-600)

The MG-600 can run asa stand alone gatherer
when the ST-600 stacker isinstalled.

HF-600 allows an operator
to feed additional signatures or sheets. The MG600 starts collating when
the signature is hand fed,
so that both signatures
combine smoothly.
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SB-09V/VF

1. Highly accurate automated set-up is performed with simple and easy
operation.
2. Book production of up to 4,000 books per hour can be achieved.
3. Both EVA hotmelt and PUR hotmelt are supported by using the interchangeable melt tanks.
4. Two application rollers ensure superior penetration of hotmelt glue.
Diﬀerences between the two system binders
SB-09V : Fully automated variable system binder equipped with roller grip style cover feeder.
SB-09VF : SB-09V equipped with rotary grip style cover feeder.

OptionBook/Cover sheet size input interface (SI-17)
All necessary setups canbe automatically performedby reading the length of
the actual book block andcover, instead of having
to manually input the size
data into the operation
panel.

Cover Feeding Section (Selectable)
Cover feeder is available in two styles. One is a roller
grip style feeder and the other is an optional rotary gripstyle feeder. Rotary grip style is designed to feed flap
covers. Any double-feeds are detected by a supersonic sensor. Both feeders are bottom feeding andthe cover can be loaded while running for continuous
operation.

Roller Grip feeder(SB-09V)

Rotary Grip feeder(SB-09VF)

Cover feeding / Scoring section
The cover scoring wheels
can create up to 4 scorelines, and can be automatically set up according to
the book thickness.

Cover registering / Nipping section
A superior nipping system
experts powerful nipping pressure to createstrong,durable binds withsharp spine corners. Automatic nipper height adjustment is available on SB09V/VF fully automated model.
4

Delivery section
The space efficient vertical conveyor and the optional
twisting conveyor LD-09T gently lay down and transport
the finished book without damaging the spine especiallyfor PUR bound books.

Perfect Binder
Melt tank section
Two application rollers
promote superior penetration of hotmelt glue into thebook for stronger binds.
Spine and side glue adjustment is done through thetouch screen.

Melt tank unit for EVA glue

Melt tank unit for PUR glue (Open drum)
Interchangeable melt tanks allow
both EVA hotmelt and PUR hotmelt to be used.

Milling section
Powerful milling, spine
preparation and extraction
for strong binding quality. Milling rotation speed
is adjustable to suit spine
preparation depending on
paper quality and bindingstyle.

OptionPre-melt tank
Glue is pre-melted in a separate, high-capacity tankand fed into the glue tank as needed. Pre-melt tanks for
EVA hotmelt (PM-20II) and for PUR hotmelt are available.

Carriage clamp
Clamp opening width can be adjusted automatically according to the book block thickness.

Connected delivery section
Operation console
Large color touch screen
provides simple and easy
operation. All necessary
set-ups can be performed
through the touch screen.

OptionWeight checking unit (WD-17)/Book rejecting unit (RU-17)
The weight checking system detects any books that are
missing a cover or signature, and delivers the erroredbooks into a reject tray.

OptionBook block feeder (BBF-SB)
Sewn book blocks or pre-glued bookblocks can be fed into the binder efficiently. BBFSB increases
productivity
by improving
book block
handling andfeeding efficiency.

In-feed section

OptionStack stream unit (SS-110)
Bound books are transported into the stack stream
orientator (SS-110) to accumulate a predetermined
number of books (up to 100 mm) for trimming in HT110. SS-110 is set up automatically according to thesetting data from HT-110. Fine adjustment is performed
through a large touch screen. The speed of the conveyor to HT-110 is also adjusted automatically.

Gathered signatures arechecked by a height detecting sensor installed on thedocking conveyor unit DC600, and inserted into theclamper while being jogged.
5Three-knife Trimmer
1. Highly accurate set-ups are performed with easy and simple
operation.
2. Trimming cycle can be adjusted in 13 stages from 400 to 1,600
cycles per hour. By accumulating 3 books at once at thestream stack orientator, productivity of 4,000 books per hour
can be achieved.
3. Rigid framing and durable structure provides the utmost intrimming accuracy.
OptionOperation console

Chip extractor (TB-100)

The trimmer is simple and easy to operate, with all necessary settings performed
through the large, iconbased color touch screen.
If the system has an error,
the error type and location are indicated for quick
resolution.

The three-knife trimming
waste is extracted by thechip extractor.

In-Feed section
A pressing unit in the in-feed section
compresses the books to remove airfor reduced bulk and accurate trimming.

OptionPlate for trimming for each size
Press plate and cutting plate for eachsize are available as options.

6

Chuck plate recognition device

Trimming section

LED lamps light up to indicate which chuck plate is suitable for each book size. Replacement of the chuck plateis fast and easy.

The height of each knife and the angle of the fore-edge
knife can be adjusted through the color touch screen
during operation. Trimmings are blown away from theknife by strong air nozzles mounted on the knife holders.

Advanced Features
PUR

Strong, Environmentally Friendly PUR Solution
Polyurethane Reactive, also called PUR, is a polyurethane adhesive attracting attention for binding strength and eco-friendliness.

Strong and Lay-Flat Binding

Durable against Temperature

As the printing industry diversifies, there is growing demand for binding with color printed sheets. EVA hotmelt glue has difficulty binding
coated stock firmly, and does not currently enable acceptable lay-flatbinding. However, PUR hotmelt glue can provide adequate binding
strength and lay-flat quality for both offset and digital prints.

PUR hotmelt glue retains durability and flexibility inboth high and low temperatures. The temperature
resistance for PUR hotmelt glue ranges from –20
to 120 degrees Celsius versus 0 to 60 degrees
Celsius for EVA hotmelt glue. This allows PUR
bound books to be handled in almost any climate
or location.

PUR hotmelt glue provides the best page spread compared to
traditional EVA hotmelt glue. High binding strength allows forthe application of a small amount of glue, allowing the pages tolay flat when the book is opened.

EVA

Ecology
PUR adhesive is environmentally friendly, allowing
PUR-bound books to be recycled. PUR also has
a lower melting point (120 degrees Celsius) than
EVA for operational energy savings.

*PUR hotmelt is reactive glue and takes time to become solidified.
Contact your local dealer about required system components forbinding with PUR hotmelt glue.

PUR

pXnet System

Manage your bindery with JDF enabled control system
The Horizon pXnet Bindery Control System is used as a central control
point to schedule work, send job data to each finisher, monitor status offinishers and collect production statistics from finishers in real-time. pXnet
brings efficiency and value in high-mix/low-volume production environments where frequent job changeovers are needed.
The pXnet system can also be interfaced with an existing workflow for
automated JDF set-up.

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System Components
CABS4000V Floor Plans
MG-600+SB-09V+HT-110 Connected

TB-100PUR
MU-09 MU-09 EVA Pre-melt
Pre-melt PUR EVA PM-20II
BBF-SB
CV-101
CVA-100 SI-17 PH-17

R-17 DC-600

S-09S

EU-600 ST-600

SB-09V

HF-600 IC2-MG600
TD-600IC2-MG600

MG-600a

MG-600b

HF-600IC2-MG600
TD-600IC2-MG600

RU-600LD-09T
WD-17 RU-17

VS-17
DB-15W

KB-17

HT-110

SS-110
Cooling Conveyor (Straight)

SSP-101

PUR
MU-09 MU-09 EVA Pre-melt
Pre-melt PUR EVA PM-20II
BBF-SB
R-17 DC-600

S-09S

SI-17 PH-17

EU-600 ST-600

MG-600a

SB-09V

MG-600b

RU-600LD-09T
WD-17 RU-17

VS-17
DB-15W

KB-17

SS-110HT-110

Cooling Conveyor(Curve)SSP-101

Cooling Conveyor(Straight)

CCG-100
CV-101
CVA-100

TB-100HT-110 Stand alone

MG-600+SB-09V Connected
PUR
MU-09 MU-09 EVA Pre-melt
Pre-melt PUR EVA PM-20II

SI-17

PH-17

S-09S

R-17

SB-09V
VS-17

LD-09T
DB-15W

MG-600 Stand alone

TB-100DC-600MG-600a
RC-15

IC2-MG600

SB-09V (S-09S) Stand alone

HC-110SB-09V (U-09S) Stand alone
VSP-09

U-09S
LD-09S

S-09S

SB-09V

CST-600

SB-09V

LD-09S

VS-17

LD-09S

VS-17

DB-15

DB-15
AC-08

8

HCG-100

HT-110EVA Pre-melt
PM-20II

VSP-09MG-600a

ST-600

SSP-101

SC-17

EVA Pre-melt
PM-20II

HF-600IC2-MG600
TD-600CV-101
CVA-100

AC-08

CABS4000V
CABS4000V Components
System Gatherer MG-600
Model name

Description

EU-600Extra connecting unit

IC2-MG600

Image checker

TD-600Book block thickness detector

ST-600On/Off-line stacker

RU-600Book block rejecting unit

HF-600Hand feed unit for MG-600H

Selection

DC-600Docking conveyor unit

CST-600

Connecting unit

CU-600Docking conveyor unit

Remarks
EU-600 is needed between MG-600 and SB-09V when WD-17 is installed.
Image checking cameras check the image of each signature to prevent incorrect loading.
TD-600 detects the thickness of gathered signatures installed on HF-600.
MG-600 is possible as stand alone .
Incorrect signatures are rejected for non-stop operation.
HF-600 allows an operator to hand feed additional signatures or sheets.
DC-600 is connecting unit between MG-600 and SB-09V.
CST-600 is docking unit for MG-600 and ST-600 off-line.
CU-600 is needed when using MG-600 with RU-600 as off-line, but possible to expand to SB-09V on-line.

Selection Selection

System Binder SB-09V/VF
Model name

Description

R-17

Connecting belt unit

S-09S

Automatic feed unit

In-feeder unit for collated book block set

U-09S

Manual feed unit

Manual feed unit for collated book block set, not possible to expand to MG-600

DB-15

Milling blower unit (Single)

DB-15W

Milling blower unit (Twin)

PM-20II

Pre-melt tankTwin type milling waste collecting unit
Pre-melt automatic feeding tank for EVA (18 liters) (Contact your local dealer about pre-melt tank for PUR.)

Pre-melt tank nozzle

Pre-melt tank nozzle set for SB-09V

VS-17

Smoke extractor unit

Smoke extractor for SB-09V

MU-09EVA

Melt tank unit for EVA glue

MU-09EVA is used for EVA glue application. (Drum rollers application)

MU-09PUR

Melt tank unit for PUR glue

MU-09PUR is used for PUR glue application (open drum). (Drum rollers application)

PH-17

LD-09S

Pre-tank-heater
Book/Cover sheet size input interface
Chute delivery conveyor

AC-08

Slope conveyor

LD-09T

Twisting conveyor

Twisting conveyor for SC-17, SCH-15 or HT-110

SC-17

Stack conveyor

When not using HT-110, SC-17 is needed as delivery unit.

Set

Set

Set
Selection

Single type milling waste collecting unit

CN-09

SI-17

Selection

Remarks
Connecting unit between MG-600 and SB-09V

RC-15

Delivery roller conveyor unit (1 m)

SCH-15

Delivery stacker

CV-101

Delivery roller conveyor unit (1 m)

PH-17 is used to heat up the EVA unit MU-09EVA or PUR unit MU-09PUR for short-make-ready of glue tank change.
SI-17 measures the book block and cover sizes, and sends the data to SB-09V.
Chute delivery conveyor for AC-08
Length 1.0 m

Delivery roller conveyor unit for SC-17
When not using HT-110, SCH-15 is needed as delivery unit.
Delivery roller conveyor unit for SCH-15

WD-17

Weight checking unit

RU-17

Book rejecting unit

WD-17 checks weight of each book.
RU-17 rejects a faulty book detected on WD-17.

BBF-SB

Book block feeder

Sewn book block or pre-glued book blocks can be fed into the binder efficiently, eliminating manual feeding.

Model name

Description

Remarks

SS-110

Stack stream unit

Bound books are transported into the stack stream orientator (SS-110) to accumulate a predetermined number of books (up to
100 mm) for trimming in HT-110. LD-09T is required.

KB-09

BridgeBridge over delivery section

KB-17

BridgeBridge over delivery section
This is needed when MG-600, SB-09V, and HT-110 are connected.

-

Cooling conveyor

Various configurations are arranged depending on space requirements.
Longer cooling conveyor is needed when PUR glue application is used.

CCG-100

Guide for curve conveyor

The guide for adjusting position of delivered book on the cooling conveyor

Model name

Description

Connecting Delivery Section

Selection

Three-knife Trimmer HT-110
Remarks

HC-110Hand feed conveyor

HC-110 is needed to feed books when HT-110 is used as stand alone.
HC-110 is 1.3 m length conveyor and its speed can be adjusted in three phases.

HCG-100

Hand feed guide set

Guide set for delivered books, installed at the entrance section of HT-110 on the cooling conveyor-

Cutting table and clamper plateCV-101
CVA-100

Delivery roller conveyor
Delivery extension conveyor

SSP-101

Automatic silicon spraying system

TB-100Trimming waste extractor unit

Cutting table and clamper plate for each size
CV-101 is 1 m length of Roller conveyor for delivery section HT-110.
CVA-100 extension conveyor which can be extended from 1.5 m to 3.8 m
SSP-101 sprays Silicon to top-Bottom knives to inhibit glue from sticking to the knives while trimming.
Recommended to use when PUR glue application is used
TB-100 uses air blowering for the trimming waste.

- Set : Need to have both unit as a set.
- Selection : Select one of the option.

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System Configurations*Contact your local dealer for more information.

Machine Dimensions and Configuration Examples [Unit : mm or inch]
18,497 or 728.3”

Example 1

SB-09V : 16,525 or 650.5”
SB-09VF : 16,592 or 653.2”

CV-101 Pre-melt MU-09 MU-09
CVA-100 Tank PUR PUR EVA PM-20II

SI-17 PH-17 VSP-09 S-09S
1,569 or 61.8”

955
or1,897 or 74.7” 37.6”

1,432
or
56.4”

BBF-SB

R-17 DC-600

DB-15W

HT-1102,865 or 112.8”

HF-600 IC2-MG600
TD-600MG-600aIC2-MG600

MG-600b

RU-6001,420 or 56.0”

VS-17

955
or
37.6”

EU-600 ST-600

SB-09V
482
or
19.0”

3,487 or 137.3”

1,400
or
55.2”

TB-100LD-09T
WD-17 RU-17

KB-17

8,745 or 344.3”

2,877 or 113.3”

SS-110895
or
510 SSP-101 35.3”
or20.1” 1,953 or 76.6”

Cooling Conveyor
Straight

2,509 or 98.8”

3,000 or 118.1”

6,410 or 252.4”
3,000 or 118.1”

2,780 or 109.5”

SB-09V : 16,525 or 650.5”
SB-09VF : 16,592 or 653.2”

1,400
or
55.2”

Pre-melt MU-09 MU-09
Tank PUR PUR EVA PM-20II

1,569 or 61.8”

SI-17 PH-17 VSP-09 S-09S

900
or
35.4”
900
or
35.4”

1,420 or 56.0”

Cooling Conveyor
Curve
3,000 or 118.1”

TB-100

955
or
37.6”

EU-600 ST-600

2,865 or 112.8”

HF-600IC2-MG600
TD-600MG-600a
RU-600LD-09T
WD-17 RU-17

KB-17

2,877 or 113.3”
3,000 or 118.1”

760
or
30.0”

3,000 or 118.1”

900
or
35.4”

7,740 or 304.8”

R-17 DC-600

1,432
or
56.4”

SB-09V
EP-09 VS-17
DB-15W

10955
or
1,897 or 74.7” 37.6”

BBF-SB

SS-1106,410 or 252.4”

HT-110
SSP-101

CV-101
CVA-100

8,745 or 344.3”

IC2-MG600

MG-600b3,655 or 143.9”

Example 2

CABS4000V

Specifications
SB-09V/VF Specifications

MG-600 Specifications

Binding TypeBinding with milling, Binding without milling and Pad binding

Module Configuration

Number of Carriage
Clamps9
Clamp width is adjusted automatically.

Number of Hopper

6 hoppers / 12 hoppers / 18 hoppers / 24 hoppers / 30 hoppers / 36 hoppers

Sheet Size

Max. W385 x L275 mm or 15.15” x 10.8”
Min. W148 x L105 mm or 5.83” x 4.14”

Bin Stack Height

Normal paper signature : Max. 300 mm or 11.81”
Coated paper signature : Max. 150 mm or 5.90”

Book Block Size

Fore-edge Length

Spine Length x Fore-edge Length

Spin

InlineeLBook Thickness

eng

th

OfflinePortrait

Max. 330 x 250 mm or 12.9” x 9.8”
Min. 148 x 105 mm or 5.9” x 4.2”

Portrait

Max. 400 x 280 mm or 15.7” x 11.0”
Min. 148 x 105 mm or 5.9” x 4.2”

Max. Transport Thickness

Max. 50 mm or 1.96”

Sheet Weight Range

Normal signature sheet

Land
Scape

Max. 330 x 320 mm or 12.9” x 12.5”
Min. 135 x 185 mm or 5.4” x 7.3”

Production Speed

Max. 6,000 sets per hour

Voltage/Frequency

3-phase 200 to 220 V, 50 or 60 Hz
3-phase 400 V, 50 or 60 Hz

1 to 45 mm or 0.04” to 1.77” (depending on conditions)
Length x Width

Cover Size

Width

LengthCover Weight Range

Machine Dimensions

Max. 400 x 660 mm or 15.7” x 25.9”
Min. 135 x 220 mm or 5.4” x 8.7”

Normal Paper : 82 to 302 gsm
Coated Paper : 105 to 348 gsm

Cover Stack HeightMax. 130 mm or 5.1”

Production Speed

Max. 4,000 books per hour

Voltage/Frequency

3-Phase 200 / 208 / 400 V, 50 or 60 Hz

Untrimmed Book Size

Machine Dimensions

SB-09VF

Finished Book Size

Trim Width

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e
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eL

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Len

eng

th

Spine Length x Fore-edge LengthMax. 410 x 320 mm or 16.14” x 12.59”
Min. 148 x 105 mm or 5.83” x 4.14”
Max. 366 x 300 mm or 14.40” x 11.81”
Min. 145 x 103 mm or 5.71” x 4.05”

Fore-edge : 45 mm or 1.77” (Maximum trim width for fore-edge is 23
mm or 0.90” when the finishing size is A4E-Landscape.)
2 to 100 mm or 0.079” to 3.93”

Trim HeightStand Alone (with U-09S, AC-08) :W4,540 x D2,585 x H1,660 mm or W185.9” x D101.8”
x H65.4”
System (with S-09S) :W4,910 x D1,685 x H1,660 mm or W193.3” x D66.4” xH65.4”

MG-600b/c : W2,860 x D1,180 x H1,690 mm or W112.6” x D46.5” x H66.6”

Top-Bottom : 30 mm or 1.18”

Stand Alone (with U-09S, AC-08) :W4,350 x D2,585 x H1,660 mm or W171.3” x D101.8”
x H65.4”
System (with S-09S) :W4,720 x D1,685 x H1,660 mm or W192.1” x D66.4” xH65.4”

MG-600a : W3,200 x D1,180 x H1,690 mm or W126.0” x D46.5” x H66.6”

HT-110 Specifications

Folded covers cannot be fed.

SB-09V

MG-600a / MG-600b / MG-600b / MG-600c / MG-600b / MG-600b

Limitations :a. Max. 50 mm (1.96”) for books which measure 145 mm (5.71”) or shorter
length between spine and fore-edge
b. Limitation for books which have a finished length of 325 mm (12.80”) or
longer between top and bottom
For example:
Max. 55 mm (2.16”) for books which measure 400 mm (15.74”) between top
and bottom before trimming
Max. 80 mm (3.14”) for books which have a length of 364 mm (14.33”)
between top and bottom before trimmingStandard Size Trimmedby Standard Accessory

A4 / A5 (±3 mm)
8.5” x 11” / 5.5” x 8.5” (±0.11”)

Clamp System
and Pressure

Operated by Servo Motor
4 kN to 12 kN (Adjustable in 9 steps)

Production Speed

400 to 1,600 cycles (Adjustable in 13 steps)

Voltage/Frequency

Three Phase 200 to 230 V, 50 or 60 Hz
Three Phase 380 to 415 V, 50 Hz

Machine Dimensions

Main Body : W1,950 x D2,150 x H1,910 (including pole lamp) mm or
W76.8” x D84.7” x H75.2”
Power Box : W510 x D1,000 x H1,450 mm or W20.1” x D39.4” x H57.1”

11

*The machine design and specifications are subject to change without any notice.
*Specifications may vary depending on the job, paper quality, environmental influences, and various other factors.
Please do a test run before starting production.

201006/CABS4000SV/02E