The print industry is undergoing a major shift as bookletmaker automation becomes essential—not just for short-run jobs, but for larger projects as well. During this webinar, Lou Ciampi, president of Independent Graphics and Andrew Bellia, president of Bellia Printing shared how the 700i Booklet System, which features the Duplo DBM-700 Bookletmaker transformed their operations with automation. Their stories highlight how automation has boosted efficiency, improved quality, and reduced job costs.
Here are some of the key takeaways from the webinar. The full recording is posted at the end.
1. Automation is a Necessity for Efficiency and Quality
As Lou of Independent Graphics put it, automation isn’t just a luxury – it’s a necessity for staying competitive and producing jobs more efficiently. Lou’s company, which offers both offset and digital printing, faced challenges with older binding equipment that required multiple touchpoints and a lot of labor. After investing in the Duplo DBM-700 and its automation, production time has been significantly reduced. Lou mentioned, “Automation is surely doing a lot of nice things for the man hours. Time is money. There are only so many hours in a day and the more things you could get done, the more things you could get out the door.”
For Andrew of Bellia Printing, the output quality from the DBM-700 surpasses that of their in-line bookletmaker. “The stuff coming out of the Duplo is first class. The difference is huge. We’re putting out a better end-product,” he said.
2. Automation Helps Address Labor Concerns
Labor shortages and rising costs remain major concerns in the print industry. Andrew noted that automation has eased the burden on his staff dealing with inefficient equipment. Employees are more willing to operate modern, user-friendly machines. He added, “I think that automating these processes helps our staff, and helps us not have to hire into the future as much. It’s not wearing on our staff as it did a couple years ago because the equipment runs a little easier.”
For Lou, automation is crucial as the workforce ages. He explained that automated equipment requires less experience to operate and makes it easier to train new hires. “The hope, with some of this automated equipment that we’re investing in, is that it won’t be such a leap of faith to train someone who’s never been in a print shop before,” he said.
3. Automation Improves Workflow and Capacity
Andrew switched to an off-line bookletmaking system to unlock more capacity from their digital presses. Running jobs in-line had slowed down the presses and reduced throughput. With the automation on the Duplo DBM-700, Andrew’s team can now run jobs 2-up, 3-up, and 4-up on larger sheets, cutting them down to maximize the sheet size.
The Duplo bookletmaker has helped both Lou and Andrew handle a wider variety of projects, from short-run booklets to long-run magazines. For Lou, the automation has sped up his workflow, particularly for 64- and 96-page saddle stitched booklets that used to take much longer to produce with older equipment.
4. Automation Improves Margins
Both speakers agreed that automation directly impacts the bottom line. For Lou, cutting man hours has improved margins on larger projects. Andrew highlighted that maximizing the sheet size by printing multiple-up and reducing the “click” charges on the digital presses has boosted profitability. For Andrew, “The more billable stuff that goes out the door, the better we are. My main savings are in the click costs.”
5. The Debate: In-Line vs. Off-line
The debate between in-line and off-line finishing solutions was a point of discussion. Andrew, who once favored in-line systems to eliminate human error, has since shifted his stance. He found that off-line finishing with the Duplo DBM-700 allowed for faster production, more control over workflow, and better reliability.
Lou prefers off-line finishing too. It allows his team to focus on specialized tasks – press operators focus on printing, and bindery operators handle finishing. This division of labor has helped increase productivity across their operations.
6. Cross-Training Made Easier
Both Lou and Andrew emphasized the importance of training and how automation has simplified the process. The user-friendly interface on Duplo’s products allows employees to quickly become proficient. Andrew highlighted the value of a unified software platform on multiple machines. He explained, “We look for equipment that runs on a similar platform. Duplo, for example, has a software platform. Everybody is familiar with the screens, and they know where the buttons are, whether using the Slitter/Cutter/Creaser or the bookletmaker. The same goes for our digital presses. Fiery runs the entire shop.”
Automation is changing the way commercial printers approach bookletmaking, offering significant improvements in efficiency, quality, and cost savings. The Duplo DBM-700 Bookletmaker is a game-changer for both short and long-run jobs. Whether you’re facing labor challenges or simply looking to improve your workflow, investing in automation can be the key to unlocking your print shop’s full potential.
Watch the full video for more insights from Lou and Andrew on how automation has improved their business.
