Tried & Tested

Thirty years old and still going strong, the Kolbus Compact casing-in line is still a giant in book binding production. When launched in 1978, it was the most cost-effective book-finishing machine of its generation and was marketed as a space-saving alternative to the manufacturer’s Flowline case binder. Its success shows no signs of abating: the Compact Line continues to outsell its closest rival, the Stahl VBF series, according to Robert Flather, Kolbus UK managing director.

The Compact did lose out to the Flowline in terms of speed: the former operated at 30 books per minute (bpm), the latter at 36bpm. But what gave the Compact its edge was the reduced wage bills – just one operator was needed thanks to one-line binding. By contrast, the Flowline consisted of several separate machines linked by conveyors, each handling a different operation in the case-binding process and requiring a separate operator.

Constantly evolving
As with any successful product, the Compact needed to keep up with change and has undergone several redevelopments. Kolbus bumped the machine’s speed up to 35bpm in 1979, then to 40bpm in 1980. Its current speed, introduced in 1999, is 60bpm.

By the end of the 1980s, on-demand book printing was gaining momentum. Average run-lengths were falling and, as a result, buyers were concentrating more on quality and makeready times. Kolbus rose to the challenge by fitting Copilot automated makeready functions on the Compact in 1990.

As a result, size could be changed automatically via a unit on the control panel that measured the case and used stepping motors to set the book transport systems. Optional extras included plastic jacketing, and improvements were made to the backing action and handling through the infeed and delivery. The case feeder was also modified, with added features such as the ability to change from a shuttle-type feed to a sucker feed at the touch of a button.

In 2004, touchscreen technology and other minor developments were made. At the same time, Kolbus introduced a sister machine: the 30bpm BF511. Although slower, the shorter run lengths, quality, fast makeready and lower price tag made it an attractive prospect.

Flather says the Compact today, “has frequently achieved ultimate perfect production at 60bpm. It regularly produces 28,800 copies on an eight-hour shift with no errors, and, as a result, the line is still selling in good numbers.”

In the secondhand arena, the Kolbus brand is established worldwide as a market leader, particularly in developing countries, according to Printing & Graphic Machinery’s Guy Churchill. In the UK, newer models like the BF 526 and 527 are popular, and the most common globally is the 523. Printing & Graphic sells at least 12 Compacts a year, and supplies a full installation service and fully refurnished models on request. It currently has three Compacts in stock.

Although the Compact’s appeal is cemented, rivals, such as the Muller Martini Diamant and the Stahl VBF, are starting to gain ground.

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SPECIFICATIONS
Speed 30-60 books/min
Formats
Max opened book case: 660x385mm
Min opened book case: 210x110mm
Max book depth: 80mm
Min book depth: 2mm
Price
New: Compact line plus pressing unit £650,000-£800,000
Used: 1998 Compact from £305,000
Used: 1996 Compact from £240,000
What to look for
• Paper handling
• Glue pots for leakage
• Teflon coatings on rubbing down station still intact