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With
over 42 years in business, producing 250 million pieces
annually, Mailmen Inc. of Hauppauge, NY is
dedicated to continuous improvement in service and internal quality.
Employing approximately 350 people, they serve large volume customers in
the financial and publishing industries.
One
of Mailmen’s customers required a special gatefold application, which
involved feeding continuously a two-up roll of paper, slitting and
nesting a piece of the original sheet to create one folded finished
piece. This application was processed once a week, which was often a
timely process to set-up. A complex gatefold such as this one, typically
a mechanic would select the various fold plates for the fold type,
measure fold panel lengths, calculate stop positions and manually set
the fold plates. Then the correct roller gap settings need to be
determined, which often takes a number of adjustments and readjustments.
With the Mathias Bäuerle Multimaster CAS 52 computer-controlled folder,
now the make-ready is set-up once, stored in memory, and then retrieved
by push button.
"A
difficult job that took us anywhere from one to three hours to set-up
now takes 15 minutes to a half-hour maximum," said Jeff Martino,
director of plant operations for Mailmen. "Set-up time becomes
production time," said Martino.
The
CAS folders have 60 fold job memory, from complex folds to simple folds.
"The flexibility of job changeover enables us to get greater
throughput," said Martino. "We have had a 30-40% increase in
productivity in certain jobs."
Flexibility
of service and quick turnaround of jobs are common requests from Mailmen’s
customers. "This folder has helped us with our main goal of
providing flexibility to our customers. Normally switching from job to
job can be timely. Now we can cut our fold set-up time in half when
switching from job to job," said William Vignola, president of
Mailmen.
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Jeff
Martino (left), director of plant operations and William Vignola (right), president Mailmen, NY
Application
Special gatefold
Solution
CAS
52/4/4 SRT
continuous
form folder
Benefits
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