Setting Up Bindery Overs for Digital Presses
BINDERY OVERS - DIGITAL PRESSES
With digital presses, the best way to handle overs for finishing operations is in the Admin->Configuration->Operations area.
Using the magnifier - go to the component record:
Toggle down to the Paper Finishing Spoils
Paper Finishing Spoils
1. Setup Spoils - For digital presses avoid using the setup spoils to calculate bindery overs. If you put in 10 sheets, this would give you 10 sheets per section on your quote. With digital we often have multiple pages in the same section. This calculation will not give you what you need if you are looking for 10 books for bindery overs. If the section has multiple pages you will only get 10 sheets regardless of the number of pages (fold-lays) in the section.
2. Rate % - This is for the running waste percent of your finishing equipment. This area is expressed as a percent. If you put in 5 it will calculate 5%. If you put in .05 it will calculate .05% which might be way less than you are looking for.
This is calculated on the sheets printed:
Number of leaves/ Number up = forms (1 leaf = 2 pages; 2 Leaves = 4 Pages - they are front and back)Number of Forms x quantity = number of sheetssheets x % = bindery running waste
3. Setup spoils per section (fold lay) - This area you want to engage for digital printing (and conventional for that matter for certain bindings). If you put in the number 1 in this place, it would give you one complete book per. Remember, it is still looking at sheets:
Number of pages / Number up = formsNumber of Forms x Setup Spoils Per Section = number of setup spoil sheets
4. Setup spoils per subsequent section (fold lay) - It is vital to put a ZERO in this section to have it calculate correctly.
5. Setup length spoils - you can ignore this section for what you are doing.
Checking the Math
If you hit the + button on the job operation in the quote it will display the spoils it is generating:
If you click on one of these (in this example Section 3 - the 10 sheets) it will show you the breakdown:
In this case there is one spoil that has come from the %, and there are 9 spoils that are being generated.
Formula:
Number of leaves / Number up = formsNumber of Forms x Setup Spoils Per Section = number of setup spoil sheets
The Math:
In our example we have 72 pages (or 36 leaves)
They are printed 4 up so this is 9 sheets
1 makeready sheet per form = 9 sheets (x 4up = 36 leaves x 2 sides = 72 pages or one complete section)
When testing it is good to exaggerate so you can see what happens to the big numbers - so if we make a second book that is 400 pages on this third section, this is the result:
The Math:
In our example we have 400 pages (or 200 leaves)
They are printed 4 up so this is 50 sheets
1 makeready sheet per form = 50 sheets (x 4up = 200 leaves x 2 sides = 400 pages or one complete section)
Add to this the 4 sheets for the waste % you get a total of 54 sheets.
This is the way we would recommend going Bindery overs for a digital press. It really speaks to how many full books you want to provide the perfect binder/coil binder as setup waste - which is usually what they are most interested in.
Related Articles
Understanding Press Spoils Components
The following are definitions for the SPOILS record of a press. Finding the PRESS SPOILS 1. These are found by going to the ADMIN tab and Choosing CONFIGURATION: 2. Click on the PRESS section under Equipment: 3. Choose the press you are looking for ...Setting Side-Specific Press Spoils
For printIQ v42 above. PRESS SPOILS – Side Specific By default, printIQ uses the reverse side of the front spoils as spoils for the reverse side makeready. The only time additional reverse side spoils are added is based on the % option. Example of a ...Setting Up A Press
1. Creating a Press Diagram of overall process to build a press (PDF available in attachments): [v39] To create a press in printIQ go to the Admin Menu and following it down to Configure Factory From here go to the EQUIPMENT section and click on ...PRESSES - Setup and configure
If you are setting up a new press or need to alter the configuration on an existing press, this is managed under Admin > Configure Factory > Equipment > Presses. This takes you to the 'Manage Presses' screen. Here you can see the list of all current ...Press Cost Component Definitions and Field Guide
The press cost component record drives the production times and the costs for the press record. There can be many component records that are engaged for different criteria. It is suggested that when building press component records you start out ...