Swindon-based print provider ESP has upgraded its digital finishing capabilities with the installation of a Tecnau BookReady B3 dynamic cut and stack system. The aim of the investment is to improve operational efficiency, reduce labour costs, and expand its offering in the publishing sector.

The new system has been configured to run inline with ESP’s Canon VarioPrint iX3000 press, with additional nearline finishing support from a Horizon StitchLiner saddle stitching line, BQ-470 and BQ-500 perfect binders, and a Horizon HT300 trimmer. ESP is also planning further upgrades to its finishing department.

According to Dave Woloszczynski, head of digital production and operations, the business selected the BookReady after seeing it at Drupa. “ESP is always looking at ways to automate the production process, to be more productive, and improve the customer experience,” he said. “We handle a high volume of short run PUR, hardcover and print-on-demand binding jobs.”

Previously, book blocks were manually jogged and trimmed from SRA3 sheets before binding. “That process relied on human intervention, which obviously has a considerable cost attached to it,” Mr Woloszczynski explained.

The BookReady system can slit, cut and stack up to B3 sheets printed in 2up or 4up imposition into final book block sizes such as A4+ and A5+, with job changes managed on-the-fly and without manual input.

“Batching the books by size and spine thickness has eliminated the need for guillotining and sorting. Now we just have to wheel the pallet of jogged book blocks straight to the Horizon binders,” said Mr Woloszczynski.

Installation and training were completed in three days. “Since then we have been running non-stop. It is operating like a dream,” he added. “It has made a huge impact on efficiency and cost savings… we can now take more work on. It will enable us to have more capacity so that we can expand into other markets and consider new opportunities, especially in publishing.”

ESP expects the investment to deliver ROI faster than the usual three-year benchmark.