Me & my: Duplo DBM600i

Over its greater than 35-year historical past ImageData Group has repeatedly invested within the newest expertise to make sure it gives its buyer as broad a variety of companies as potential. And this expertise repeatedly wants refreshing as older machines come to the tip of their pure life.

This was the case final 12 months when the corporate’s present Duplo 350 bookletmaker began taking part in up. The corporate, which operates from three totally different places throughout the UK, had had the machine for round seven years and had produced greater than 6 million books on it, in accordance with Jason Vivian, operations director at ImageData’s Brighton website.

“The machine had effectively exceeded its typical lifespan,” says Vivian. “It was beginning to get actually difficult to make use of and was displaying indicators of fatigue, which was mirrored within the completed product.”

ImageData’s Brighton operation usually offers with small-format digital jobs and the on-demand, short-run nature of this kind of work meant the outdated machine was now not as much as the duty in hand. 

“We’re continuously altering from one job to a different and the job setup on the Duplo 350 was time consuming,” says Vivian. “It will additionally battle with sure substrates like coated shares, so we have been having handy feed work and the operation was turning into much less productive. On the similar time we have been capable of print A4 panorama on our iGens and this work was turning into far more widespread, however the outdated Duplo 350 couldn’t end them so we have been both having to outsource work or end them by hand. We wanted one thing that was quicker, strong, extra heavy responsibility and will do A4 books.”

Consequently, the corporate began scouring the marketplace for options final summer time. The search was narrowed right down to a bookletmaker from IFS or from Duplo. Fortuitously for ImageData its search coincided with Duplo providing a refurbished DBM600i on the market.

“The timing was excellent,” says Vivian. “We have been cursing our luck with the outdated machine and we had began to discover various choices after which this machine got here alongside which was lower than 12 months outdated and had round 500,000 books on the meter. So we went to Duplo’s showroom to see it in motion. It regarded all-singing and all- dancing to us so we did the take care of Duplo and put in it final summer time.”

He provides that Duplo did a “unbelievable job” on the refurb. A few of the components have been changed and Vivian says nobody would have recognized it was secondhand as a result of it regarded nearly as good as new. Because the machine was a refurb it additionally meant that it ran out “significantly cheaper” than different choices so signing on the dotted line was a no brainer. The truth that ImageData is a long-standing consumer of Duplo equipment additionally helped.

“We’ve been a buyer of Duplo for close to on 30 years so we now have a protracted established relationship,” says Vivian. “We’ve acquired excellent binders, folders and creasers from Duplo.”

Set up ran easily. “It was delivered on day one, put in on day two after which we have been coaching on the afternoon of day two. It solely took a few hours to coach the operators up on it.”

Acquainted expertise

Though the machine is radically totally different in some ways to the mannequin it changed at ImageData, basically underpinning it’s the similar tried and trusted expertise with quite a lot of fashionable twists that improve productiveness. The DBM600i is a totally automated stitching, folding and trimming gadget that makes use of ultrasonic expertise combining the DSC-10/60i Collator Towers and the DBM-600 bookletmaker and trimmer. It has greater than 25 configurations that may mix suction, collators, sheet feeders and slit, minimize, crease, squarefold and three-knife trimming operations.

The DBM600i encompasses a touchscreen PC controller that’s consumer pleasant and permits jobs to be arrange in seconds relatively than minutes. It will possibly run at a most pace of 5,200 booklets per hour on paper shares from 64-300gsm. It takes a most sheet measurement of both 350x508mm or 230x610mm. ImageData put in it with further DBM600 fore-edge trimmer and DSF6000 digital sheet feeder modules.

“The machine is totally automated,” says Vivian. “The operator-friendly touchscreen management means the job arrange time is fast so there may be much less downtime. It will possibly deal with most sorts of media; I don’t suppose we’ve come throughout a bit of inventory that we will’t run via it. It’s very correct and the completed product is of a top quality. It’s quicker, extra strong and it’s saved us cash. As well as we’re now capable of produce A4 panorama books on it.”

Since set up Vivian says the DBM600i has run like a dream and even when there have been some minor teething points these have been rapidly ironed out by Duplo. “They provide an excellent, top quality service,” he says. “9 out of ten occasions in the event you put in a name within the morning they may get an engineer out to you later the identical day or if not then very first thing the following morning, not that we’ve needed to put in lots of requires this machine. In comparison with the Duplo 350 the quantity of downtime and engineer exercise has considerably diminished.”

Consequently he struggles to seek out any flaws with the brand new machine. “I actually can’t consider something,” says Vivian. “We’re actually pleased with it. It’s important to perceive what we have been coping with beforehand the place we have been actually pulling our hair out. It’s a luxurious to have what we’ve acquired now.”

The one minor snag he can discover with the machine, which he admits is one thing that Duplo can’t actually do something about, is the paper curling situation related to digital printing.

“Our digital presses run at excessive speeds and sizzling temperatures, which crucifies paper,” says Vivian. “Due to paper curling we now have had some points with feeding, however I couldn’t pinpoint a specific software or inventory and say ‘sure, that’s going to provide us issues’ and I’ve to say that in comparison with what we had earlier than that is an absolute dream.”

As for what he notably likes in regards to the new machine he rattles off a protracted checklist of attributes together with reliability, high quality of labor produced, pace, diminished downtime, ease of use and suppleness.

“We do all sorts of totally different stuff on it – brochures, monetary studies, magazines, menus – in a wide range of codecs and sizes, from A6 as much as A4. It’s extremely versatile.”

Due to this prolonged checklist of attributes Vivian says he wouldn’t hesitate to advocate the machine to different printers and may the necessity ever come up he would positively purchase one other DBM600i, due to the transformative impression it has had on the corporate’s ending capabilities.


Max thickness 3mm (30 sheets of 80gsm)

Min paper measurement 105x170mm

Max paper measurement 350x508mm or 230x610mm

Completed booklet sizes 105x75mm-350x254mm

Max pace 5,200bph

Worth New fashions begin from £77,000 (relying on configuration)

Contact Duplo 01932 263900

Firm profile

ImageData Group was established in 1983 by Roger Birkin who’s the present chairman. The agency operates throughout three websites: the top workplace is in Willerby, East Yorkshire, and offers with litho and display work, the Howden website, additionally in East Yorkshire, handles large-format digital and the Brighton website does digital small-format jobs. The group handles work from a variety of purchasers in several enterprise sectors, from retailers and corporates throughout to the general public sector. It employs circa 220 employees throughout the three websites and has an annual turnover of round £23m.

Why it was purchased

The corporate had an present Duplo 350 bookletmaker, which had produced greater than 6 million books and was beginning to present indicators of damage and tear. ImageData was experiencing a rising quantity of downtime on the machine, which needed to be hand ate up event. As well as, the Duplo 350 was not able to producing A4 landscapebooks, which was a quickly rising space for the enterprise and needed to be outsourced.

How has it carried out

The introduction of the DBM600i at ImageData’s Brighton website has had a transformative impact. The corporate is now capable of produce A4 books in-house and downtime has been nearly fully eradicated. “On account of the truth that it’s quicker, has a faster job arrange, is extra productive and we now not need to outsource work, it has 100% saved us cash,” says Vivian.

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