Oversized large format printing commands a lot of attention. However, folding large pieces down to a manageable size is often the neglected part of producing the job. Standard-sized folding equipment isn’t able to handle oversized printing so graphic arts industry professionals need to know what can and can’t be done and where to turn for post press conversion.
What Is Large Format Folding?
Most standard-sized folding equipment has a maximum width of 30-inches. Therefore, large format folding is any product with a width dimension greater than 30-inches. There is an exception though. If the width is less than 30-inches but the length exceeds 60 inches, the job is still considered to be large format.
Like any other folding job, preplanning and technical knowledge are critical for ensuring customer expectations are met. As an example, let’s consider a press sheet measuring 40” x 72”. The narrow dimension, the 40-inch width, must fit within the mouth of the folder, meaning it must be run on an appropriate-sized piece of equipment. Then, six-feet of paper (72-inches) must work its way from the continuous feeder into the folding plates. Not only does the paper have to get there, six feet of stock must clear the first fold plate prior to the next sheet entering.
The sheer size of the product being handled means that the concept of “high speed” in large format folding is drastically different from the normal or miniature folding worlds. When planning turnaround times, your customers’ expectations should be set in the 1,000 to 3,500 sheets per hour range, depending on the specific factors of each job.
Big Folding Techniques:
Typically the best way to handle a large sheet is to begin by getting the product’s length down to a manageable size. Accordion folds work well because the very nature of the fold allows the product to remain flexible in the right angle section. This flexibility is an important factor because the more pliable a sheet the less stress it will endure, resulting in less wrinkling or gusseting. Once in the right angle section the product is brought down to its final size.
Equipment and Staffing Costs
The labor required to staff oversized folding machinery is another cost consideration. Most binderies set upper limits on total paper poundage employees can effectively handle on an hourly basis. Large format stock weighs significantly more than normal-sized paper. For example, the same 40” x 72” sheet weighs about three times a typical-sized 25” x 38” sheet of equivalent stock. Naturally, more labor will be required to handle the extra tonnage, not only on the loading end, but also in offloading and packing.
A Market Opportunity
When talking about oversized folding, maps are usually the first thing that comes to mind. However, there are many other viable market segments. Think along the lines of posters, kids growth charts, schematics, promotional items, signage and direct mail.
The Rickard Advantage:
At Rickard Bindery, we have some of the largest folders in the Midwest. With a fleet of folders capable of sheet sizes up to 44 x 80 when can handle sheets from the largest of oversized presses. Whether your project is a few thousand or a few million, we have the right machinery for the job. Give us a call to see how we can help you get the job done.
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