Saddle-stitching System StitchLiner5500

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 Stitch Fold Accumulate and Score Collate
saddle-stitching system which incorporates flat ACF-30
sheet gathering, scoring, folding, stitching and
three-knife trimming in line. ST-40

The StitchLiner5500 provides user-friendly VAC-100

operation, high productivity and versatility for

SPF-30
the on demand, production print, and trade
bindery environments. HTS-30

Delivery
Fore-edge Trim
Head and Foot Trim

Bookletmaking Workflow in StitchLiner5500

Waste box is not included.

 StitchLiner5500 Features

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 Accumulator/Folder : ACF-30

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.
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 icon-
based 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 two-
up booklet production.
 Accumulator/Folder

ACF-30

Accumulate and Jog Sheet Flow in ACF-30 and Scoring / Folding Process

The gathered 4-page signatures are Registration with Transportation with

Short Edge Guide Long Edge Guide
accumulated, jogged, registered and
transported at a right angle
(landscape) to the scoring section. Scoring
The jog guides are adjusted
automatically according to the sheet
size input on the SPF-30.

Scoring
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 Saddle-stitcher Continuous Folding Jogging
tight fold on a thick booklet. SPF-30

Accumulator/Folder
ACF-30

Stacker/By-pass Unit
Plow-fold
ST-40
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.

SPF-30
LCD Touch-screen
The complete line is set-up and controlled at the SPF-
30’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.
Stitching
Booklets up to 10 mm thick (50 sheets of normal 80
gsm paper) can be stitched on the SPF-30 saddle-
stitcher. 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
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.
Saddle-stitcher
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.
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 center-
cut device, the system can produce two-up booklets. An
optional loop stitching kit is also available.
Reject Tray
Only accurately stitched booklets are
transported to the three-knife trimmer.
Faulty sets are delivered to the reject
tray for efficient, non-stop operation.
Staple Detect Sensor
 Three-knife Trimmer

HTS-30

Fore-edge Trimming Sheet Flow in HTS-30 and Trimming Process

Saddle-stitcher
The servo-motor controlled feed
SPF-30
mechanism provides for accurate
booklet registration and fore-edge
trimming. The guide is automatically
Three-knife Trimmer
adjusted according to the sheet size
HTS-30
input on the StitchLiner touch-screen. Fore-edge Trimming

Booklet Registration
Head-Foot Trimming
The head and foot of the booklet are
trimmed accurately, and trimming
waste is smoothly extracted from the Head-Foot Trimming
trim box to a movable chute with a
powerful air blower. An optional
center knife device can be fitted for
two-up booklet production.

Delivery Conveyor
Finished booklets are neatly delivered
to the exit conveyor. An optional Delivery to
preset kicker PK-30 separates a batch the Exit Conveyor
of booklets at a predetermined count.

Options
Stitching Head
Standard stitching head (#23 to #25-
thickness: 0.6 mm to 0.5 mm) and
optional stitching head (#25 to #27-
thickness: 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.)
Loop Stitching Kit
An optional loop stitching kit can be
fitted to the standard stitching heads.
Trim Waste Blower: TB-30
Powerfully extracts trim waste from the
three-knife trimmer.
Waste box is not included.
Options
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.
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.
 StitchLiner5500 Major Specification VAC-100 Major Specification
Max. 350(W) x 500(L) mm (13.7" x 19.6") Module Type VAC-100a, VAC-100m, VAC-100c
Sheet Size Min. 140(W) x 206(L) mm (5.6" x 8.2") Number of Bins 10, 20, 30, 40, 50, 60
(Optional support guide is required to the VAC-100 under 148 mm (5.9") in width.) Max. 350(W) x 500(L) mm (13.7" x 19.6")
Normal Paper : 60 to 210 gsm Sheet Size 5 Min. 120(W) x 148(L) mm (4.8" x 5.9")
Sheet Weight Range
Coated Paper : 80 to 210 gsm (Optional support guide is required under 148 mm (5.9") in width.)

Stitch Thickness Max. 5 mm (0.2") (Book Thickness 10 mm (0.4")) Sheet Weight Range 5 52 gsm to 208 gsm
Stitch Distance 66 to 150 mm (2.6" to 6") Folded Sheets 5 Under 104 gsm for 8-page fold
1
Stitch Head Standard Equipment: 2 (Optional stitching head is available for 4 stitches.) Bin Pile Height 55 mm (2.2")
#23 to #25 (0.6 mm to 0.5 mm) Feed System Air Suction Feed System
Stitch Wire Range 2
Option #25 to #27 (0.5 mm to 0.4 mm) Overlap Utmost / Long / Medium / Short (4 step shifts)
Booklet Size (Before Trim) Max. 350 x 250 mm (13.7" x 9.8") Collate Distance Automated Set-up Function / Variable Function
(Head-Foot x Fore-edge) Min. 140 x 103 mm (5.6" x 4.1") Production Speed Max. 8,000 sets/hr. (A4 - 8.5" x 11" / 10 sheets / straight stacked)
(Up to 85 mm / 3.4"
Fore-edge 95 to 230 mm (3.8" to 9") depending on a condition.) Double Cycle : Divides the VAC-100 system into two
144 to 312 mm (5.7" to 12.2") (When center base is installed.) sections for continuous operation.
Booklet Size (After Trim) 120 to 152 mm (4.8" to 5.9") (When center base is removed.) Dual Cover Feed : Uses the top two bins as cover
Head-Foot (When center base is installed Programming Features
186 to 312 mm (7.4" to 12.2") and center-cut is not performed.) sheet feeding bins for continuous operation.
(A booklet size when center-cut is
90 to 153 mm (3.6" to 6") performed.) Preset Tab Sheet : Inserts tab sheets on the first or
Trimming Width 2 to 25 mm (0.08" to 1") second bin at the head of the towers.
Production Speed 5,500 / 5,000 / 4,400 / 3,700 / 2,900 booklets (1 block feeding) 3 Stacker Type ST-20R Pile Height : 320 mm (12.5")
Receiving Trays 6
Voltage / Frequency 3-Phase 200 V, 50 / 60 Hz, 220 V, 60 Hz, 400 V, 50 Hz Jogger Type PJ-77R Pile Height : 90 mm (3.5")
50 Hz 9.4 A (Max. 17 A) Voltage / Frequency 3-Phase 200 V, 50 / 60 Hz, 220 V, 60 Hz, Single Phase 230 V, 50 Hz
3-Phase 200 V
4
60 Hz 8.9 A (Max. 17 A) 3-Phase 200 V 50 / 60 Hz 9.9 A
Rated Current
3-Phase 220 V 60 Hz 8.6 A (Max. 13 A) Rated Current 3-Phase 220 V 60 Hz 10.4 A
3-Phase 400 V 50 Hz 4.7 A (Max. 9 A) Single Phase 230 V 50 Hz 10.4 A
50 Hz 2.6 kW 50 Hz 1.4 kW
3-Phase 200 V 3-Phase 200 V
4
60 Hz 2.5 kW 60 Hz 1.5 kW
Power Consumption Power Consumption
3-Phase 220 V 60 Hz 2.6 kW 3-Phase 220 V 60 Hz 1.7 kW
3-Phase 400 V 50 Hz 2.6 kW Single Phase 230 V 50 Hz 1.8 kW
ACF-30 260 kg (573.3 lb) HTS-30 1,000 kg (2,205 lb) Motors 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)
Machine Weight
SPF-30 760 kg (1,675.8 lb) TB-30 100 kg (220.5 lb) Machine Weight 290 kg (639.5 lb)
1 3 stitches are available as factory option. 5 Specification for VAC-100 itself, or VAC-100+ST-40 connection.
2 Optional stitching head is required. Refer to the specification of StitchLiner5500 when using as a part of the system.
3 Production speed will be lower in multiple block feeding. 6 Required VAC-100c tower for the right side delivery.
4 Not include VAC-100 and ST-40.
4,240 (167.0")
Installation Space 500
(19.7") 3,240 (127.6")
500
(19.7")

ST-40 Major Specification Unit : mm (inch)

Maintenance Maintenance

(19.7")
Maintenance
500
2,180 (85.9") 1,060 (41.8")
Max. 350(W) x 500(L) mm (13.7" x 19.6") Max. Height : 1,961 mm

400 860 (33.9")

1,060 (41.8")
Sheet Size 5
SPF-30 ACF-30
Min. 182(W) x 128(L) mm (7.2" x 5.1") (77.2") (VAC-100) (Saddle-stitcher) (Accumulator
5 /Folder)
Sheet Weight Range 52 to 208 gsm
(15.8")
Stack Pile Height 360 mm (14.1")
3,930 (154.8")
1,400 (55.2")

ST-40

3,859 (152.0")
Sheet Delivery Thickness Max. 6 mm (0.23")

1,957 (77.1")
HTS-30 (By-pass
(Three-knife Stacker)
Production Speed 5 Max. 8,000 sets/hr. (A4 - 8.5" x 11" / 10 sheets / straight stacked) Trimmer)

Voltage / Frequency Single Phase 200 V, 50 / 60 Hz, 220 V, 50 / 60 Hz, 230 V, 50 Hz

1,270 (50.0")

50 Hz 3.6 A (Conveyor)

810 (31.9") 810 (31.9") 810 (31.9") 810 (31.9") 810 (31.9") 842 (33.2")
Single Phase 200 V VAC-100a

7,909 (311.4")
8,909 (350.8")
60 Hz 3.4 A (Collator)

Rated Current 50 Hz 4.8 A

Single Phase 220 V VAC-100m
60 Hz 4.5 A (Collator)

Single Phase 230 V 50 Hz 4.7 A

VAC-100m
Power Consumption Single Phase 200 V 50 / 60 Hz 660 W (Collator)

Motors 100 W x 1, 60 W x 2 VAC-100m

(Collator)
Machine Weight 126 kg (277.8 lb)
5 Specification for VAC-100 itself, or VAC-100+ST-40 connection.
VAC-100m
Refer to the specification of StitchLiner5500 when using as a part of the system. (Collator)

VAC-100m
(Collator)
(19.7")
Maintenance
500

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
030527/SN/STL5500/00E/SV