‘Exactly how we want to produce’

Print Solutions

Bonacia, which is located in the English city of Woodston, Peterborough and prints all of its products digitally, has optimised its processes for softcover and hardcover production by investing in a Vareo perfect binder and InfiniTrim three-knife trimmer inline duo. The purchase agreement for the two machines was signed at the Muller Martini stand at the Hunkeler Innovationdays in Lucerne.

‘Bonacia is the power behind the print!’ – with this motto, the digital printing company, which was founded in 2005, is run by a group of young millennials and employs 95 people and quickly made a name for itself because of its innovative print products. The creative company has won more than a dozen awards over the past two years for its books, booklets, manuals and numerous other products, which appear in ten different market segments, including BookPrintingUK, Young Writers, Spiderwize and Nursery Leaver’s Books.

Most of the company’s orders are ultra)short runs of as few as one copy per title. For this reason, a lean and continuous production process, from the printing press to distribution, that is as highly automated as possible is essential for Bonacia. ‘We have four long term goals,’ said production director Carl Whitelock. ‘Reduce overtime, reduce changeover times, reduce manual interventions and reduce unit costs.’

Starting this spring, a major contribution towards achieving these objectives will be made by a Vareo perfect binder with EVA hotmelt conveyor system and an InfiniTrim three-knife trimmer from Muller Martini. Bonacia opted for the in line duo, thanks to the tour of the Muller Martini world at the Print Finishing Centre and the Bookbinding Academy in Switzerland. Carl said, ‘The demonstrations were world class. In particular, the presentation of the Connex workflow system appealed to us. It is exactly how we want to produce in the future.’

The investment also means more efficiently and therefore more cost effectiveness than the company’s current solution. Bonacia’s financial experts calculated the return on investment precisely. They had received a much cheaper offer for machines produced by their previous supplier. However, the calculations showed that the Muller Martini equipment would pay for itself much quicker.

Carl signed the purchase agreement for the two systems at the Hunkeler Innovationdays in Lucerne. At the Muller Martini stand, he also saw how his new dream team together with the new end sheet feeder, also from Muller Martini, can now produce hardcover book blocks in runs of one on an industrial scale for the first time. Bonacia has not yet planned to integrate the end sheet feeder, ‘but we will take a serious look at this option for the future,’ said Carl.

From left to right: Ross Tee, Carl Whitelock (both Bonacia) and David McGinlay (Muller Martini Great Britain) in front of the Vareo perfect binder at Hunkeler Innovationdays.

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