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Combining the efficiency and ease of operation of flat sheet collating with the productivity, versatility and quality of a saddle-stitching system.
The StitchLiner5500 is a pioneering new concept for the demanding printing and publishing environments, bridging the gap between traditional collating and bookletmaking and conventional saddle binding lines.
The Horizon StitchLiner5500 is an innovative saddle-stitching system which incorporates flat sheet gathering, scoring, folding, stitching and three-knife trimming in line. The StitchLiner5500 provides user-friendly operation, high productivity and versatility for the on demand, production print, and trade bindery environments.
Stitch Fold Accumulate and Score
Fore-edge Trim Head and Foot Trim
Bookletmaking Workflow in StitchLiner5500
Waste box is not included.
At up to 5,500 booklets/hr., the quick-changeover StitchLiner5500 is ideal for short, medium and long production runs. The interactive icon-based touch screen and end-to-end automation allow even less experienced operators to achieve fast, easy job set-ups and changeovers. Horizon’s 4-page signature concept eliminates the time-consuming intermediate folding process required for 8- and 16-page formats. The U-shaped layout is floor-space efficient and very convenient for the operator to monitor work in progress.
Collator : VAC-100 Up to six 10 bin VAC towers can be combined to create a sixty-station gathering system. Advanced programming functions, double cycle mode and dual cover feeding, allow you to reload the stations without interrupting the run for maximum productivity and efficiency. The VAC-100 system towers can be divided in any combination to deliver collated sheets into the StitchLiner5500 system or high capacity stacker at the left side, while collating straight sets into the receiving tray on the right side of the system. Stacker/By-pass Unit : ST-40 The ST-40 is a by-pass stacker connecting the VAC-100 system to the ACF-30. Errored sets are delivered to the build-in reject tray for non-stop operation. Any purged sheets in the reject tray can be manually processed via the hand feed station. The ST-40 also serves as a high-capacity offset or straight stacking device. Accumulator/Folder : ACF-30 Sheets are accumulated by section, scored, plow-folded, and delivered onto the saddle. The number of sheets per folded section can be varied to insure a tight fold, depending on sheet count, grain direction, or paper weight. Saddle-stitcher : SPF-30 The SPF-30 can stitch a book up to 10 mm thick. An iconbased touch screen on the SPF-30 sets-up and controls the complete StitchLiner system. The StitchLiner5500 is equipped with heavy-duty Hohner stitching heads for accurate, reliable center stitching. Three-knife Trimmer : HTS-30 The HTS-30 in-line three-knife trimmer provides complete, high-quality three-sided finishing in one pass. All trimming parameters are input at the centralized touch-screen with full automation. An optional center-cut device provides for twoup booklet production.
Accumulate and Jog
The gathered 4-page signatures are accumulated, jogged, registered and transported at a right angle (landscape) to the scoring section. The jog guides are adjusted automatically according to the sheet size input on the SPF-30.
Sheet Flow in ACF-30 and Scoring / Folding Process
Registration with Short Edge Guide Scoring Transportation with Long Edge Guide
The jogged set is precisely scored on the center of the sheet. The number of sheets per folded section can be divided and then scored to insure a tight fold on a thick booklet.
The scored sheets are folded reliably along the score line by a continuous series of forming rollers. The pressing rollers insure a sharp, tight fold.
The complete line is set-up and controlled at the SPF30’s interactive icon-based touch screen. Each finishing station -- the ACF-30, SPF-30 and HTS-30 - is automatically set-up in less than 30 seconds (A4 to A5 / 8.5" x 11" to 5.5" x 8.5") by simply inputting the sheet size. Up to 100 different complete jobs can be saved into memory for instant job recall. Any production errors, such as a jammed sheet or skewed fold are recorded for easy viewing in the record/error window. This provides complete system status at a glance for easy production management.
Booklets up to 10 mm thick (50 sheets of normal 80 gsm paper) can be stitched on the SPF-30 saddlestitcher. The folded sections are jogged from the head and foot, centered on the saddle by a centering mechanism, and then stitched to produce accurately stitched booklets. The stitch wire length is automatically adjusted according to the book thickness. The system comes equipped with two Hohner stitching heads, and up to two additional stitching heads are available as option. With the HTS-30’s optional centercut device, the system can produce two-up booklets. An optional loop stitching kit is also available.
Error Set Detect Sensor
Advanced error detecting sensors are located throughout the system, to identify for example booklets without a stitch or a skewed fold. Only correctly completed booklets are delivered to the exit conveyor.
Staple Detect Sensor
Only accurately stitched booklets are transported to the three-knife trimmer. Faulty sets are delivered to the reject tray for efficient, non-stop operation.
The servo-motor controlled feed mechanism provides for accurate booklet registration and fore-edge trimming. The guide is automatically adjusted according to the sheet size input on the StitchLiner touch-screen.
Sheet Flow in HTS-30 and Trimming Process
The head and foot of the booklet are trimmed accurately, and trimming waste is smoothly extracted from the trim box to a movable chute with a powerful air blower. An optional center knife device can be fitted for two-up booklet production.
Finished booklets are neatly delivered to the exit conveyor. An optional preset kicker PK-30 separates a batch of booklets at a predetermined count.
Delivery to the Exit Conveyor
Standard stitching head (#23 to #25thickness: 0.6 mm to 0.5 mm) and optional stitching head (#25 to #27thickness: 0.5 mm to 0.4 mm) are provided. Additional stitching heads are available for up to 4 stitches per booklet. (3 stitches are available as factory option.)
Center-Cut Device: CC-06/CC-08/CC-1/4
6 mm (0.24") standard gutter (Max. book thickness: 3 mm / 0.12") and 8 mm (0.31") gutter (Max. book thickness: 4 mm / 0.16") are prepared. Two-up booklet production utilizing the center knives provides efficient book production at 11,000 booklets/hr.
Loop Stitching Kit
An optional loop stitching kit can be fitted to the standard stitching heads.
Preset Kicker: PK-30
According to a preset number input on the touch-screen, a booklet is skewed to easily identify and separate the end of a series.
Trim Waste Blower: TB-30
Powerfully extracts trim waste from the three-knife trimmer.
Waste box is not included.
StitchLiner5500 Major Specification
Sheet Size Max. 350(W) x 500(L) mm (13.7" x 19.6") Min. 140(W) x 206(L) mm (5.6" x 8.2")
(Optional support guide is required to the VAC-100 under 148 mm (5.9") in width.)
VAC-100 Major Specification
Module Type Number of Bins Sheet Size
VAC-100a, VAC-100m, VAC-100c 10, 20, 30, 40, 50, 60 Max. 350(W) x 500(L) mm (13.7" x 19.6") Min. 120(W) x 148(L) mm (4.8" x 5.9")
(Optional support guide is required under 148 mm (5.9") in width.) 5 5
Sheet Weight Range Stitch Thickness Stitch Distance Stitch Head Stitch Wire Range Booklet Size (Before Trim) (Head-Foot x Fore-edge)
Normal Paper : 60 to 210 gsm Coated Paper : 80 to 210 gsm Max. 5 mm (0.2") (Book Thickness 10 mm (0.4")) 66 to 150 mm (2.6" to 6") Standard Equipment: 2 (Optional stitching head is available for 4 stitches.) #23 to #25 (0.6 mm to 0.5 mm) Option #25 to #27 (0.5 mm to 0.4 mm) Max. 350 x 250 mm (13.7" x 9.8")
Sheet Weight Range Folded Sheets Bin Pile Height Feed System Overlap Collate Distance Production Speed
52 gsm to 208 gsm Under 104 gsm for 8-page fold 55 mm (2.2") Air Suction Feed System Utmost / Long / Medium / Short (4 step shifts) Automated Set-up Function / Variable Function Max. 8,000 sets/hr. (A4 - 8.5" x 11" / 10 sheets / straight stacked) Double Cycle : Divides the VAC-100 system into two sections for continuous operation.
Min. 140 x 103 mm (5.6" x 4.1") (Up to 85 mm / 3.4" Fore-edge 95 to 230 mm (3.8" to 9") depending on a condition.) 144 to 312 mm (5.7" to 12.2") (When center base is installed.) 120 to 152 mm (4.8" to 5.9") (When center base is removed.) 186 to 312 mm (7.4" to 12.2") and center-cut is not performed.) (A booklet size when center-cut is 90 to 153 mm (3.6" to 6") performed.) 2 to 25 mm (0.08" to 1") 5,500 / 5,000 / 4,400 / 3,700 / 2,900 booklets (1 block feeding) 3-Phase 200 V, 50 / 60 Hz, 220 V, 60 Hz, 400 V, 50 Hz 3-Phase 200 V 50 Hz 60 Hz 60 Hz 50 Hz 50 Hz 60 Hz 60 Hz 50 Hz 9.4 A (Max. 17 A) 8.9 A (Max. 17 A) 8.6 A (Max. 13 A) 4.7 A (Max. 9 A) 2.6 kW 2.5 kW 2.6 kW
(When center base is installed
Booklet Size (After Trim)
Dual Cover Feed : Uses the top two bins as cover sheet feeding bins for continuous operation. Preset Tab Sheet : Inserts tab sheets on the first or second bin at the head of the towers.
Trimming Width Production Speed Voltage / Frequency
Stacker Type Jogger Type
Pile Height : 320 mm (12.5") Pile Height : 90 mm (3.5") 9.9 A 10.4 A 10.4 A 1.4 kW 1.5 kW 1.7 kW 1.8 kW
Voltage / Frequency 3-Phase 200 V, 50 / 60 Hz, 220 V, 60 Hz, Single Phase 230 V, 50 Hz 3-Phase 200 V Rated Current 3-Phase 220 V Single Phase 230 V 3-Phase 200 V Power Consumption 3-Phase 220 V Single Phase 230 V Motors Machine Weight 50 / 60 Hz 60 Hz 50 Hz 50 Hz 60 Hz 60 Hz 50 Hz
3-Phase 220 V 3-Phase 400 V 3-Phase 200 V
3-Phase 220 V 3-Phase 400 V ACF-30 SPF-30
2.6 kW 260 kg (573.3 lb) HTS-30 1,000 kg (2,205 lb) 100 kg (220.5 lb) 760 kg (1,675.8 lb) TB-30
1,200 W x 1, 400 W x 1, 200 W x 1, 100 W x 1, 60 W x 1 (only a,c towers) 290 kg (639.5 lb)
1 3 stitches are available as factory option. 2 Optional stitching head is required. 3 Production speed will be lower in multiple block feeding. 4 Not include VAC-100 and ST-40.
5 Specification for VAC-100 itself, or VAC-100+ST-40 connection. Refer to the specification of StitchLiner5500 when using as a part of the system. 6 Required VAC-100c tower for the right side delivery.
400 860 (33.9") (15.8")
Sheet Weight Range Stack Pile Height Sheet Delivery Thickness Production Speed Voltage / Frequency
3,930 (154.8") 1,400 (55.2")
52 to 208 gsm 360 mm (14.1") Max. 6 mm (0.23") Max. 8,000 sets/hr. (A4 - 8.5" x 11" / 10 sheets / straight stacked) Single Phase 200 V, 50 / 60 Hz, 220 V, 50 / 60 Hz, 230 V, 50 Hz Single Phase 200 V 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 50 / 60 Hz 3.6 A 3.4 A 4.8 A 4.5 A 4.7 A 660 W
Single Phase 220 V Single Phase 230 V
Power Consumption Motors Machine Weight
Single Phase 200 V
100 W x 1, 60 W x 2 126 kg (277.8 lb)
5 Specification for VAC-100 itself, or VAC-100+ST-40 connection. Refer to the specification of StitchLiner5500 when using as a part of the system.
The machine design and specifications are subject to change without any notice. Distributed by
510 Kuze Ooyabu-cho, Minami-ku, Kyoto, 601-8206, Japan Phone : +81-(0)75-934-6700, Fax : +81-(0)75-934-6708, www.horizon.co.jp
500 (19.7") Maintenance
7,909 (311.4") 8,909 (350.8")
810 (31.9") 810 (31.9") 810 (31.9") 810 (31.9") 810 (31.9") 842 (33.2")
1,957 (77.1") 3,859 (152.0")
Max. 350(W) x 500(L) mm (13.7" x 19.6") Min. 182(W) x 128(L) mm (7.2" x 5.1")
500 (19.7") Maintenance
ST-40 Major Specification
Unit : mm (inch) Max. Height : 1,961 mm (77.2") (VAC-100)
500 (19.7") Maintenance
500 (19.7") Maintenance