Tried & Tested

A flat-sheet gatherer that could also collate folded sections and books was unheard of when the Col-Tec Signature collator launched in 2002. First shown at Graph Expo in Chicago, it took a while for the market to be convinced of the benefits of such an unusual device. As a result initial uptake was slow - the manufacturer produced only one Signature collator for every five conventional flat-sheet collators it manufactured, but today 50% of its production are Signatures.

The machine was targeted at printers and trade finishers who were hand-feeding single- to four-clamp perfect binders. “These were people who didn’t have expensive fully automatic lines,” explains Col-Tec managing director Paul Bailey. Instead they were hand-gathering folded sections and then feeding them into their binders. “So we thought why not develop a cheaper alternative with a smaller footprint.”

One of the main advantages of the Signature, according to Bailey, is that its competitors all work on a similar technology in that they use a drum feeder, but “Col-Tec is different because it’s a top-loading flatbed feeder which is cheaper, more versatile and has a smaller footprint”, he claims.

Because the machine can collate folded sections and bound books, its appeal has been widened to the mail-fulfilment market, such as mail-order catalogues and direct mail.

Over the past couple of years, improvements have been made to the machine to cement its success. When it was first introduced it was limited to the total set thickness of 40mm, but over the past six years this has more than doubled to 100mm. “As a result we had to design special conveyor belts that would allow you to collate at that depth and set thickness,” says Bailey.

Optional extras include sensors built into the machine so if the operator loads the collator incorrectly the error will
be detected. A computer-programming module allows customers to use the collator for random collating. There is also an offset stacking mechanism at the end of the delivery stacker that allows the operator to separate each set in
the stacker.

Yearly service contracts, which involve maintenance visits every four months, are offered for both new and used machinery. Col-Tec also offers a 12-month parts and labour warranty for new and used machines. The manufacturer has four service and installation engineers.

When buying used, check the condition of the conveyor belt, the flites and the condition of the suction head as this might need rebushing to give it back its rigidity. A six-year-old Signature with 12-months warranty will usually cost around 50% of its new price.

SPECIFICATIONS
Max sheet size 350x350mm
Min sheet size 80x100mm
Max speed 4,500 cycles per hour on feeders
Stock range Flat sheet to folded sections to stitched and perfect bound books
Price New eight-station feeder with exit delivery stacker: £45,000, similarly configured used six-year-old with 12-month warranty: £22,500
What to look for
• Conveyor belts
• Flites
• Suction heads