Book Printing and Manufacturing

Edwards brothers Malloy has three offset printing facilities the second oldest of the three is our Jackson Road facility in Ann Arbor it was built in 1960 and found it as Malloy lithographic today it encompasses more than a hundred and eighty thousand square feet and features some of the most advanced book manufacturing equipment in our industry we begin our tour in the plate room in 2005 we installed one of the first fully automated book plate making systems in North America two redundant lines cover over 2,000 square feet of floor space three plate setters and for imaging heads produced 12 to 15 thousand aluminum printing plates per month it takes just six minutes to produce the first plate from start to finish in two additional minutes per plate after that the entire system can be run with just one Operator per shift the system is designed for just-in-time processing allowing Edwards brothers Molloy to move customer’s orders to press with great efficiency next we’ll take a look at two of our cutting-edge web offset presses our Jackson Road facility became home to the first Timpson x’ web press to be installed in the United States back in 1982 since then we’ve added seven more tips ins on Jackson Road and there are now a total of fifteen timpz ins deployed throughout Edwards brothers Molloy representing the largest fleet in North America in 2006 we brought online this zero maker ad machine t8 as it is called here to handle workbooks and similar size products it occupies roughly 4,000 square feet and is capable of printing one in two color jobs at speeds of up to 1300 feet of paper per minute the addition of a folder and a pallet Iser make this press fully automated another press that is similar to t8 is t7 and it is a workhorse of production for books sold in the trade market an entire addition to the building was added specifically for this machine it is also fully automated reducing the workload and staffing needed to produce jobs in a matter of minutes t7 and t8 are some of the most advanced web presses in our lineup and make printing large quantities of books incredibly cost-effective for publishers we also use sheet that presses it in our this is one of our cover presses which uses Heidelberg zani color technology to render stunning color and detail in quantities as low as 75 copies Edwards brothers Malloy operates one of the most expansive network of digital book centers in the country we have a total of 11 digital book centers 10 located across North America and one in the UK our print local program allows publishers to print closer to their customer saving both time and shipping cost books printed in any one of our digital book centers need not be restricted to a specific trim size this enables us to use the most cost-effective equipment offset or digital to meet the demand for customers books we offer a troop EOD solution without compromise we use a film laminator in UV coater at the Jackson Road facility to apply protective coatings to the covers of books added in 2010 the film laminator can apply heated film to print a paper at about 180 feet per minute the UV coater applies a thin layer of coating to covers at about 6000 sheets an hour these two machines exemplify how

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Edwards brothers Malloy provides high quality products at low cost – its publishers now let’s take a look at the binder e3 binders take up over 19,000 square feet in the back of this facility binder 2 is the most highly automated of the 3 added in 2002 binder 2 sports a cola later with 14 feeders and can produce about 13,000 book blocks per hour at top speed binder 2 feeds a brand-new state-of-the-art trimmer built by Muller martini the trimmer operates at six thousand cycles per hour and can potentially trim about 18,000 books an hour at top speed the cutting-edge equipment in the bindery ensures that the time-consuming and difficult task of quality book making is done fast and done right one of the newest additions to the Edwards brothers Malloy equipment profile is the Diamont case line added in the spring of 2011 the case line is capable of churning out thirty five case bond books per minute the addition of a Vesta inline jacketing machine allows dust jackets to be added to finish books as they leave the line the new case line is just one in a series of investments made by Edwards brothers Molloy to deliver lower cost and higher quality services to publishers Edwards brothers Malloy handle storage and fulfillment for many of its customers close to twenty thousand square feet of storage space is used to store books that will be shipped to destinations all over the world six dedicated workers fulfill thousands of orders every day one of the most advanced aspects of this operation is our state of the art inventory management software customers can log in and see real-time data on inventory tracking and shipping a unique feature of the Jackson Road facility is the error screen filtration system first installed in 1993 and upgraded in early 2004 the filtration system collects more than two and a half tons of scrap paper each day and shoots it through 2,500 feet of pipe to two compactors located in the back of the facility where it is picked up for transport to a recycling facility this specially designed scrap retrieval system is an integral part of a comprehensive recycling program that urn the Jackson Road operation zero landfill status in September of 2009 no manufacturing waste is sent from this building to a landfill the cornerstone of our operation is not a piece of equipment or anyone facility it is the team of customer service professionals who help publishers manage their titles being printed at Edwards brothers malloy our CSRs has been with the company for an average of more than 20 years their extensive experience and knowledge gives them the ability to truly make our customers job easier you

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