63 www.printmonthly.co.uk Issue 359 - March | April 2026 in the long run. When evaluating a bookletmaker, Harry says automation should be top of the checklist. He explains manual setup, complex changeovers, and machines that rely heavily on operator experience quickly become bottlenecks. As such, PSPs should be looking for systems that minimise makeready, automate adjustments, and offer repeatability regardless of who is running the machine. “Build quality, feeding reliability, modular scalability, and the ability to cope with a wide variety of stocks are also critical, especially in digital environments where coated stocks and static can cause ongoing headaches,” he explains. Engineer Efficiency Into Finishing Harry goes on to say that this was the exact thinking behind Duplo’s latest high-production solution in the iSaddle SENSHI. He explains the latest innovation has been designed for those businesses producing high volumes of short-run and mixed-work jobs, where productivity is determined not by top speed alone, but by how little time is lost between jobs. “It combines the speed and durability of traditional saddle stitching with the convenience and automation of flat-sheet finishing,” he says, continuing: “Fully automated setup through a PC-based controller allows operators to recall jobs, change formats, and adjust scoring, stitching, folding, and trimming in under a minute. That makes it ideal for environments where dozens of jobs may pass through the system every shift. “Its modular architecture also reflects how real print businesses operate. Multiple lines, multiple towers, block feeding, and load-on-the-run capability allow continuous production while the next job is being prepared. That dramatically reduces downtime and wasted stock. Features such as intelligent feeding, auto-reject of incomplete books, and simultaneous block change aren’t gimmicks. They are practical tools designed to keep production flowing and margins protected. SENSHI can produce flat, well-aligned booklets up to 120 pages, with consistent folding and accurate trimming, which Harry says makes it suitable for higher-value applications such as corporate brochures, educational publications, and professional reports. Also from Duplo is the existing DBM-700, which Harry describes as a “proven solution” for printers that need high productivity across both digital and litho workflows. Its modular design means it can be configured around real-world requirements, from near-line digital finishing to high-volume multi-press environments. An optional square spine module on the machine has also proved popular with customers, offering them the ability to deliver stitched books with a perfect-bound appearance. This, Harry says, opens up higher-margin applications without adding complexity to the workflow. “The common thread across all successful booklet operations we work with is simple: they invest in automation, they reduce reliance on manual skill, and they focus on consistency,” Harry says, adding: “Bookletmaking is absolutely still big business, but profitability now belongs to those who engineer efficiency into their finishing, rather than trying to push more volume through outdated workflows.” Intelligent Automation Ed Hudson, UK general manager at Plockmatic Group, which counts Morgana and Intec among its core brands, says that despite the diversification of digital print Bookletmaking is absolutely still big business, but profitability now belongs to those who engineer efficiency into their finishing ▲ The iSaddle SENSHI is designed for producing high volumes of short-run and mixed-work jobs BOOKLETMAKERS | ROB FLETCHER
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