Modern folding technology allows for a great deal of production flexibility. There are many processes that can now be performed inline with folding to reduce turnaround times and increase overall quality:

Gluing – Fugitive and seam gluing can be performed inline with folding for efficient production of direct mail pieces, booklets and other products. For example, a project can be folded and glued inline to form a pocket. Accordion and gate folding capabilities allow for many layout and design options. At E&M Bindery, we can perform up to 14 accordion folds and double parallel gate folds to handle even the most complex projects.

Planning Tip - For most gluing applications, inks and coatings should be knocked out of the gluing area. If this cannot be done on your project, we may be able to find a glue that can still offer proper adhesion.

Scoring and Perfing – There are a few ways to combine scoring and perfing with folding to create an inline process. Scoring can be performed directly on a folder at high production speeds for fast turnaround. Another option is rotary scoring, which offers a higher quality score than folder scoring. Rotary scoring allows for right-angle and start-stop perfing, can be performed inline with scoring, slitting, gluing and folding for efficient production.

Planning Tip - Projects with brittle inks and coatings typically require a high-quality score prior to folding to prevent cracking. Rotary scoring may be the best solution, as the quality is equivalent to that of die scoring - with much higher production speeds and lower costs. Involve E&M Bindery during project planning to determine if rotary scoring should be performed on your pieces.

Labels – Many direct mail applications call for high-speed, inline label application. Our Label-Aire label application capabilities allow us to apply labels during folding for efficient production. With running speeds of up to 18,000 per hour and application tolerances of 1/16”, label application is as precise as it is fast.