November 28, 2007 - How Ripon Printers enhanced its business growth possibilities, and its profits, with the Muller Martini Bolero perfect binder
Ripon Printers employs 330 people and has revenues of $44 million annually. The entire staff of print production professionals at Ripon is committed to superior customer service, responding to the needs of a client list that includes small to mid-size catalog marketers and publishers along with producers of directories, manuals and softcover educational products.  Now, Ripon Printers, which is located in Ripon, Wisconsin, has added state-of-the-art perfect binding technology to its production floor.
Specifically, Ripon installed a Muller Martini Bolero perfect binder to complement its existing business as well as to create new opportunities for growth.  With the Bolero being their first binder from Muller Martini, their expectations are for it to boost their bottom line both immediately and into the future.  The installation was completed in March, 2007 and it didn't take long for Ripon to begin gaining solid return on its investment.  "We are now open to two new markets: PUR and layflat binding," explains Andy Lyke, President of Ripon Printers.
Broadening service capabilities
The Bolero perfect binder offers the widest product range of any adhesive binding technology - including hot melt, cold glue or PUR in perfect bound, layflat or book blocks for casing-in, and, sewn books.  Bolero can also handle the industry's most diverse hard and soft cover book sizes for 1-up and 2-up production.
In particular, the ability to process PUR adhesive (polyurethane reactive) is providing extensive sales growth possibilities for companies such as Ripon Printers, as more and more customers are specifying PUR perfect binding due to its high pull resistance values and outstanding layflat characteristics.  "The addition of PUR binding, combined with the ability to perform layflat binding, has broadened our line of service," states Mr. Lyke.
Comprehensive support from Muller Martini
Among the key factors in making the installation of the Bolero perfect binder a success at Ripon Printers is the support Ripon has received from the Muller Martini team of installers and technical advisors.  "With regard to the installation, Muller Martini was very timely and responsive during the overall installation period. It was a very positive experience," says Andy Lyke.  Furthermore, thanks to Muller expertise, actual implementation of the new equipment went extremely well and Ripon Printers was able to get up and running efficiently in a very short period of time.  "Overall the start-up went very smooth, it was on time with no glitches," continues Mr. Lyke.  "And in terms of production support, when there were questions Muller Martini responded very quickly and immediately addressed any issues."
Increasing operational efficiencies
Raising productivity and at the same time lowering overall production expenses have of course become highly important strategies for today's printing and print finishing operations.  Ripon Printers realized these benefits almost immediately after the Bolero perfect binder was installed.  "From a performance standpoint, the machine is running very well," states Mr. Lyke.  "It produced at almost full machine speed during the first month of production."
The 8,000 cycle-per-hour Bolero perfect binding system is the most advanced adhesive binding technology on the market today, creating books with optimal ease of operation.  Using a JDF/JMF-ready interface and fully automated operation across the entire size range, Bolero eliminates time-consuming steps by completing make-readies digitally in moments, virtually on its own - allowing the quickest job preparation possible and significantly reducing the costs associated with labor. 
Jobs can be generated 100% from digital data, either from Bolero's intuitive and user-friendly touchscreen, through an optional measuring station, or via JDF files. Motorized make-ready adds further efficiency and productivity, enabling the shortest set-up times of any adhesive binding system. In addition, on the fly adjustments allow optimization and adjustment without stopping running production, and, job recall makes repetitive book production fast and convenient. What's more, Bolero delivers impeccable binding quality, due in part to unique cross brushing action that ensures consistently superior spine preparation.
"The Bolero fits our needs for reducing our make-ready times and for consistent production. The splitting saw has enabled us to increase production and lower our labor costs," sums up Mr. Lyke of Ripon Printers. 
For further information about the Muller Martini Bolero perfect binder, please call 1-888-2-Muller or visit www.mullermartiniusa.com.