Scoring and Folding for Digital Tri-fold Brochures

[tngcas]

Our shop has been using a table-top folder (Duplo DF-990A) to do tri-fold brochures but we are having trouble with it and our volume on trifold brochures has grown so we are thinking of upping our game on those. We are having to spend a lot of time cleaning the rollers and it's getting to be impractical/wasteful. We are doing maybe 5-10k a week right now. I have no idea if that's a lot but it feels like a lot for the little table-top folder when it's jamming and we have tight turnaround-times.

We haven't had good luck using our Duplo SCC to score brochures first for several reasons:

1. The SCC's don't really do a great job feeding text weight paper without constant db feeds
2. The SCC's are being constantly used for other larger jobs.
3. Getting the scores to lineup with the table-top folder is nearly impossible.

We'd ideally like to have a setup that can score and fold together and we have very limited floor space. We need to be able to do 104gsm to 218gsm gloss and matte paper.

What are you guys using and/or what would you recommend?

Thanks!

 

[ReproElectroProspero]

Our shop has been using a table-top folder (Duplo DF-990A) to do tri-fold brochures but we are having trouble with it and our volume on trifold brochures has grown so we are thinking of upping our game on those. We are having to spend a lot of time cleaning the rollers and it's getting to be impractical/wasteful. We are doing maybe 5-10k a week right now. I have no idea if that's a lot but it feels like a lot for the little table-top folder when it's jamming and we have tight turnaround-times.

We haven't had good luck using our Duplo SCC to score brochures first for several reasons:

1. The SCC's don't really do a great job feeding text weight paper without constant db feeds
2. The SCC's are being constantly used for other larger jobs.
3. Getting the scores to lineup with the table-top folder is nearly impossible.

We'd ideally like to have a setup that can score and fold together and we have very limited floor space. We need to be able to do 104gsm to 218gsm gloss and matte paper.

What are you guys using and/or what would you recommend?

Thanks!

Sounds to me that the problem is the folder. Friction feed will always be a pain when using glossy stocks. Whatever solution you go with, try and make sure you have air suction feed as that will help you a lot.

Another thing to check is proper grain direction. The only times we ever have to score a sheet before folding are if it's on a very thick stock, and if we've cut the paper in such a way that the fold is going across the grain of the paper fibers instead of with it.

 

[SoggyWinter]

I was impressed with Horizon's creaser folder at Printing United last year for both build quality, and support. Cost is 40k USD give or take

CRF-362 Creaser/Folder - Standard

The Standard Horizon CRF-362 Creaser/Folder has been designed to handle the unique requirements of creasing and folding digital color output across a wide range of light and heavy weight stocks, coated or uncoated. Creasing and folding can be done in one pass for easy and accurate processing of...

www.sdmc.com

 

[pippip]

We use a morgana auto creaser and major folder. Absolute workhorses, very well made.

Haven't used one but the Morgana Digifold I think would be a good shout as can do both in one.

 

[Pennypicher]

Duplo sells a CP 375 creaser/folder that can do weights up to 400 gsm in 1 pass. Rather than 2 different machines. Its accurate and fast. Seen lots of them out in the field. Yes a bit $$ but it works.

 

[Robohopar]

I use the Morgana digi fold pro XL. It’s a beast and it just keeps running. I want to say it’s rated for 80lb and/or 20lb paper but it sucks. However once you get into 28lb paper ir paperweight a bit higher and all the way up to 16pt, it has no issues. Comes with a hefty price tag but we do about 5-10k runs a week and I love it.

Are you running 20lb regular paper?

 

[tngcas]

Thanks everybody! I'm going to get quotes on the pieces mentioned here.

Are you running 20lb regular paper?

We rarely run 20lb paper. We don't even stock it, it's a special order for us. Our standard lightest paper is 28lb that way we can order in bulk and save a few pennies since our distributor gives us a discount if we order a specific number of cases.

 

[iDigiPrint]

We use Morgana Digifold Pro that creases and fold in one machine. Floor space is minimal. Never had any problems with it for the last 4 years. We are currently running a digital (Ricoh 7210) 6000 qty trifold job on 100 gloss text that has the maximum 300% ink coverage and the Morgana folds without any cracks and consistency is spot on. We are also using the optional thin stock creasing matrix. 20-28# uncoated paper we run on a stahl. Never tried it on the Digifold after hearing it doesn’t work well with light stocks. If I needed another digital folder, it would definitely be a Morgana.