June 22, 2007 -- Hauppauge, New York – Cadmus Cenveo produces more than 300 wire-stitched monthly magazines at its plant in Easton, Pennsylvania, most of which are personalized. A new PrimaPlus SB AMRYS (Automatic Make-Ready System) line from Muller Martini, with no fewer than 24 feeders, provides impeccable-quality selective binding of the products.

Cadmus Cenveo, which employs 3,300 people, is the world’s largest producer of scientific and technology magazines as well as medical trade magazines. The company is the fifth-largest printer of periodicals in North America. In addition to its Easton, Pennsylvania location and its headquarters in Richmond, Virginia, Cadmus Cenveo also has three other production facilities located in Lancaster, Pennsylvania, Easton, Maryland, and Baltimore, Maryland. All five plants print 300 million pounds of paper every day.

Saddle Stitcher Line with 24 Feeders
One of the latest Cadmus Cenveo investments is in Easton, Pennsylvania, where approximately 400 wire-stitched and perfect-bound magazines are manufactured every month utilizing a Muller Martini PrimaPlus SB AMRYS saddle stitcher for selective binding. The complete system, installed in April 2006, encompasses no fewer than 22 flat pile feeders, a product feeder and a card gluer, inside/outside inkjet, Robusto compensating stacker, film-wrapping and shrink line, as well as short and long Streamfeeders for automatic signature feeding. It is the longest PrimaPlus selective binding line Muller Martini has ever installed anywhere in the world.

The approximately 320 magazines, wire-stitched in Easton, Pennsylvania, have an average circulation of 25,000 copies. The majority of these are subscriptions, which are sent to the readers’ homes via mail. About 80 percent of the periodicals are personalized. Sixty percent are addressed inline with an inkjet system. Another 20 percent are not only addressed, but also have varying content. For example, the advertising pages are changed, depending on the available subscriber data.

Saving Time with Repeat Jobs
“With so many different titles,” says General Manager and Vice President Dan Rodriguez, “Fast set-up and changeovers are very important, in addition to production speed. For that reason, we chose the PrimaPlus SB AMRYS. Thanks to the Automatic Make-Ready System, we save a lot of time, because we have almost nothing but repeat jobs and can recall the same settings and parameters time and time again.”

In addition, according to Dan Rodriguez, the new saddle stitcher is easy to operate: “Five machine operators spent a week at a course in Muller Martini’s Training Center in Switzerland. After that, they quickly had the machine under control. We are therefore satisfied with the new line in every aspect.”

Adjusting the Entire Press Delivery System Fully-Automatically with AMRYS

A few months after installing the PrimaPlus SB, Cadmus Cenveo also installed a new AvantiPlus bundle stacker in Easton, Pennsylvania – along with a Forte compensating stacker and 443 palletizing system. It’s not only the first Muller Martini bundle stacker in this plant, but it’s also the first with the horizontal design concept. “After we commissioned our new Goss press, which prints 55,000 copies per hour, we needed a new bundle stacker and looked at systems from six different suppliers,” says Plant Manager Frank Donnelly. “The AvantiPlus, with its exceptional bundle quality and its high degree of automation, impressed us the most.”

Cadmus Cenveo also relies on two new AvantiPlus – with Forte compensating stackers, 443 palletizing system as well as Floorveyor and Topveyor transporting systems – at its headquarters in Richmond, Virginia. This is the first fully AMRYS-integrated press delivery system in the world. With the exception of the air, all parameters of the bundle stackers, compensating stackers, palletizers and conveyors relating to size changes are adjusted fully automatically-controlled via the Macos system developed by Muller Martini.

Plant Manager John Leuth is enthusiastic about the new solution: “Thanks to the high bundle quality, we’ve been able to increase production speed on the Corona C18 from 11,000 to 16,000 cycles per hour.” In addition to the high performance perfect binder, three other Muller Martini systems are loaded with bundles from the AvantiPlus in the Cadmus Cenveo plant in Richmond: a Normbinder softcover line as well as two saddle stitchers, models 300 and 301.

This summer, two new Muller Martini perfect binders will begin operation at Cadmus Cenveo. Of particular note is the fact that only a short time after acquiring Cadmus at the end of 2006, the new owner Cenveo ordered two Boleros for the Easton, Maryland and Lancaster, Pennsylvania plants – proof positive that the new parent company also has full confidence in Muller Martini’s solutions.