Doveton Solves Finishing Bottlenecks with New Booklet System

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Deveton press
(Right to left) Jason Davies, Duplo UK Regional Sales Manager, Mark Savage, Doveton Press Managing Director.

Bristol based Doveton press has bought and installed a new Duplo DBM-600 Booklet system which joins their new Duplo DuBINDER DPB-500 Binder installed earlier this year. These investments come after analysing their workflow and the current crop of equipment over the course of the pandemic.

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Deveton press
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Deveton press

Mark Savage, Managing Director said “With the level of jobs being reduced through the pandemic, our Anicolor 52 hadn’t been turned on since the end of February, there just wasn’t any work for it. All our jobs have and are going through our Heidelberg XL75 and our digital presses. We had a good look at our workflow, the people and equipment and ended up selling the Anicolor to make space for the Duplo DBM-600 Booklet System.”

“We were having major problems with our finishing bottlenecks in both cutting and folding. With the speed and versatility of the Duplo booklet system means that both folding and guillotine processes have now been freed up along with other equipment as we can put a wide variety of jobs through the machine, from simple folding and collating to our short run booklet work. Currently we’re putting all our standard folded leaflets through the booklet maker since we get so many different jobs for them, they just block up the folders and the saddle-stitcher. I do think that once the volumes start to come back, we will be putting more and more work through the Duplo booklet system as it just eats the work up!”

“This is the third Duplo booklet machine we’ve installed, and we’ve always been happy with them. They’re robust, they produce excellent products consistently and my operators know the intuitive software inside out.”

The Doveton DBM-600 booklet system integrates two 10/60i intelligent towers, with the highly flexible and easy to use DBM-600 booklet maker. The connection to the DKT-200 Trimmer provides a completely automatic 1 (fore-edge) plus 2 (head and foot) knife trimming operation. This allows the operators at Doveton to take the printed SRA3 or B3 sheet directly from the press and finish the book in one operation, providing huge savings on guillotining and labour costs. Altogether the system allows for A4 landscape booklet production as well as 10,000 booklets an hour when running 2-up.

“I’ve had the pleasure of working for Gavin and Mark Savage for over 20 years and have watched and helped them grow over the year.” Says Jason Davies, Duplo Regional Sales Manager. “It’s a great fit for the team due to the ease of use and not having to fold sections makes it the most effective system in today’s market. They can run just a few digital books right up a large litho run without breaking a sweat! They are always keen to move with technology and embrace the changes in print. This is their third booklet maker with us as well as a DC-746 fully automatic slitter, cutter, creaser with dynamic perforating. Here’s to the next 20 years!”

Savage continues, “We used to outsource all our digitally bound books, but the Duplo DPB-500 binder is simple and provides excellent quality. We had been debating on whether to bring our binding work in-house for over 10 years. We simply did not have the expertise to do this finishing process. But the new binder from Duplo is so easy to use, and with this new generation of hot melt glue we can bind in the morning and ship high quality trimmed finished books out in the afternoon. It’s made our binding so much more flexible for our 3mm – 5mm spine work. It has taken some getting used to but we’re steadily building our bookwork jobs that we used to turn away.”

“Logically our next step will be to increase our print capacity, but our current premises will not allow for this. Our main factory is based in the ex-service depot of a 19th Century prison and is a warren of passageways and rooms. Much of our surrounding area has been snapped up by property developers and so we’re looking to move in the near future. The priority will be to keep all our people together, there’s no point moving location if we have to lose our valuable people in the process so for now, we will wait and see.”

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