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Walsworth Publishing

Smyth sewn book binding — From the left: Shane Hutson (Walsworth, Manager), Manrico Caglioni (Book Automation, President), Francesco Mussita (Meccanotecnica, CEO). In the back: the Universe Sewing Sheet-fed.

06 Feb 2017

Finding the right solution for sewing digitally printed flat sheets

Walsworth is a family-owned company that employs more than 1.250 people.
With more than 75 years of experience in printing high-quality books, we know how to put a book into print. Our state-of-the-art web, sheet-fed and digital presses accommodate small print runs of hundreds of copies, to large print runs of several hundred thousand copies. And, if the product lifecycle requires frequent reprints of smaller quantities and quick fulfillment, our flexibility allows us to meet the customer’s need.

CHALLENGE

We had to find the right solution for sewing digitally printed sheets and additionally to combine digital with offset printing for the yearbook production. With run lengths becoming shorter and digital printing becoming a powerhouse, we need to bridge the technology gap between digital and traditional sewing.

SOLUTION

After the successful introduction of a Universe Sewing, one more unit has upgraded our division.

UNIVERSE book sewing machine allows digital printers, publishers and trade binderies to get top book finishing quality within short to medium runs production of digitally printed books. The most common applications are variable content publications, such as photo books, yearbooks, and catalogs of luxury brands.

RESULTS

Meccanotecnica’s technology has significantly reduced the cost of producing digitally printed smyth sewn book binding; additionally, it has contributed to streamlining the yearbook production.

Advantages are evident in the paper handling due to the fact that now we move the entire job while in the past we had to handle only folded signatures. Furthermore, we now automatically add personalized pages to offset books or vice versa, an offset signature to a digital book. We rationalized the process and reduced the man-hours required for the job. Steps such as folding, material handling, or collating are no longer required.

UNLOCKING EFFICIENCY AND PRECISION IN DIGITAL BOOK SEWING

Book Automation’s Smyth sewing machines are more than just equipment—they are strategic enablers for printers navigating the evolving demands of modern book production. By automating formerly manual steps such as folding, gathering, and signature handling, these systems unlock new levels of productivity while preserving the craftsmanship and durability associated with traditional bookbinding. Their versatility allows for seamless integration of digital and offset components within a single workflow, enabling the creation of hybrid books with personalized sections and premium finishing.

If you're looking to bridge the gap between short-run digital printing and high-end sewn book quality, we invite you to explore our lineup of Smyth sewing machines for digitally printed flat sheets and discover how Book Automation can help elevate your production capabilities.

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Case study

Walsworth - Case Study [453 Kb.]

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