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Bourg Booklet Maker (BM-e) In-Line / Off-Line / Near-Line / Dual-Mode

Bourg Booklet Maker (BM-e)

The Bourg Booklet Maker (BM-e) is C.P. Bourg’s high-end award winning booklet maker that utilizes the latest technology with unparalleled quality and speed to produce on-demand booklets. The paper flow follows a stitch–fold–trim process with guaranteed set integrity, a maximum of 120 pages per booklet (30 sheets) and a maximum speed of 5,000 booklets/hour – the best of its category.

Large sheet sizes of 370 x 600 mm (14.57 x 23.62 in) can be processed through the BM-e with ease and create, for example, oversized B3 calendars formats and A4 (US letter) landscape booklets.

To accommodate offset production needs, the BST-e collator can also be connected to the BM-e.

Within the BM-e, the paper-path can follow either a right to left process - and work In-Line with the HP Indigo 5500, 5600 and 7000 Series Digital presses - or a left to right process - and work In-Line with Xerox printers- offering a great flexibility!

Furthermore, the color touchscreen interface (GUI) and the automated tool-less set-up capability makes the booklet maker very easy to use.

The BM-e responds to the needs of commercial printers and in-plant printing institutions that  have shorter turnaround time, smaller job runs and tightening budgets.

Highest quality and speed booklet production

Final dimensions of booklets produced by the BM-e range from 70 x 119 mm (2.75 x 4.68 in) up to 300 mm x 370 mm (11.81 x 14.57 in) to a maximum speed of 5000 booklets/hour - the best of its category.

The BM-e is able to stitch fold trim up to 30 sheets, stitches up to 55 sheets, and folds up to 120 pages booklets without marking, scuffing or scratching.

The maximum trimming distance is 25 mm (0.98 in). Booklets produced can therefore be of an extremely small size.

As the book press is integrated in the folder, booklets are systematically flatter and more aesthetically-pleasing.

Like others C.P. Bourg booklet makers, the possibility of automatically measuring the thickness of each booklet in operation is a standard in our equipment. This enables you to have zero waste and increase your productivity.

Great connectability

The BM-e is designed to be connected directly to a wide range of production digital printers/presses such as Xerox and HP Indigo but also to various C.P. Bourg products.

The BM-e can work with the Bourg Sheet Feeder (BSF), which is designed to dramatically improve the efficiency of Near-Line production finishing for environments with on-demand printing, including collated digital variable data print (VDP) output. By being connected to the BSF, the BM-e also integrates the advantages of Off-Line and In-Line finishing, ideal for customers hesitating between Off-Line and In-Line finishing (see the description of the BSF).

The BM-e also accepts sheet outputs from Bourg’s proven BST-e Suction Tower typically used with analog printers/presses.

The Near-Line application BSF – BCM-e – BM-e is an ideal solution for digital printers/presses. Output from any engine (digital or pre-collated offset) can easily be placed into the Bourg Sheet Feeder (BSF). Through this solution, sheets will follow an automated bleed, crease, stitch, fold, trim process to create booklets of up to 120 pages (30 sheets).

In brief, the BM-e uniquely integrates with your current and future workflow.

Media / Sheet sizes Media sizes
STANDARD FEATURES
Features Advantages Benefits
Fully symmetrical machine
  • The paper-path can follow either a right to left process or a left to right process
  • The paper-path direction can be changed after installation
  • The BM-e works both In-Line with the HP Indigo 5500, 5600 and 7000 Series Digital presses and with Xerox printers
  • Flexibility to change the In-Line press/printer
Folds up to 120 page booklets
Stitches up to 60 sheets
  • Stitch fold trim up to 30 sheets (75 gsm)
  • Top/corner stitches up to 55 sheets (without fold nor cut)
  • Ability to process jobs with more content
Graphical User Interface (GUI)
  • User-friendly industrial grade color touchscreen
  • Single GUI for entire finishing line can be connected wirelessly to any tablet, smartphone or computer
  • Easy to use interface
  • Control your entire finishing remotely
  • Remote diagnostics, statistics and much more
In-operation adjustments
  • Job adjustments can be performed via the GUI "Run" menu
  • Fine tuning adjustments of stitch, fold, trim while BM-e is in operation
Stitch fold module
  • Automatic stitch head adjustment
  • Heads can be disengaged
  • Unique folding belt technology applies a maximum pressure of 300 kg (661 lbs) via book press
  • Automatic top, corner, side, or saddle stitching
  • Flatter booklets
2 to 4 stitch heads
  • 2 to 4 Hohner or Deluxe heads
  • Large range of stitching possibilities
DELUXE head features
  • Tool-less cassette replacement
  • Plug & Play stitch heads
Purge feature
  • Automatic ejection of faulted jobs enabling continuous production
  • Minimal time lost to faulty jobs
Eject tray
  • Secondary exit for jobs that do not require folding
  • Enables ejection of faulty jobs
  • Multipurpose secondary exit
  • Can be used as small stacker
Visible straight paper path
  • Complete job visibility
  • Ease of intervention and traceability
OPTIONS
FEATURES ADVANTAGES BENEFITS
Loop Stitch
  • Hohner can accommodate a loop kit
  • Offers extra stitching possibilities
  • Ideal booklet binding style for bound material meant to be inserted and used in a ring binder
Trim module
  • Self-adjusts to booklet thickness
  • Blade-against-blade trimming
  • Fully automated trimming
  • Highest quality cuts
Barcode reader capabilities 1D and 2D
  • Automatic integrity check
  • Automatically process variable data jobs
  • Automatic job setup
  • Guaranteed job integrity
  • Saves time configuring/processing variable data jobs
JDF automation with the bourg box (bb)
  • Full automatic job setup
  • Workflow integrity check
  • Touchless Web-to-Finish workflow
  • Maximize throughput and time between jobs
  • Minimize potential for human errors and waste
  • Optimize turnaround time
Interface Feeder Booklet maker (IFB)
  • Automatic ejection of job in case of double feed or wrong barcode
  • Minimal time lost to faulted jobs
  • Enables manual feeding of faulted jobs
Dimensions Dimensions
Media (IN OFF-LINE MODE)
Maximum speed 5,000 booklets/hour (5 A4 sheets, 90 gsm)
Paper weight 60 to 350 gsm
SAddle stitching
Minimum paper size 119 x 180 mm (4.68 x 7.08 in)
Maximum paper size 370 x 600 mm (14.57 x 23.62 in)
Booklet thickness (with fold and cut) 2 to 30 sheets of 75 gsm or equivalent (cover included)
TOP/side stitching
Minimum paper size 119 x 170 mm (4.68 x 6.69 in)
Maximum paper size 370 x 300 mm (14.57 x 11.81 in)
Booklet thickness (without fold nor cut) 2 to 55 sheets of 80 gsm or equivalent (cover included)
Folding/trimming
Minimum paper size 119 x 70 mm (4.68 x 2.75 in)
Maximum paper size 370 x 300 mm (14.57 x 11.81 in)
Booklet thickness (fold and cut) 2 to 30 sheets (8 to 120 pages) of 75 gsm or equivalent (cover included)
Face trimming 0 to 25 mm (0 to 0.98 in)
Physical
Dimensions of BM-e (Stich Fold module) (L x W x H) 177,5 x 71 x 155 cm
(69.88 x 27.95 x 61.02 in)
Dimensions of trim module (optional) (L x W x H) 69 x 71 x 155 cm
(27.16 x 27.95 x 61.02 in)
ITE (only necessary if connected to a collator BST-d / BST-e) 27 cm (10.63 in)
ISF (only necessary with some printers) 37,3 cm (14.68 in)
Delivery conveyor 87,5 cm (34.44 in)
Input/output paper path without ITE 86 cm (33.85 in)
Input/output paper path with ITE 61 cm (24.01 in)
Weight of BM-e (Stich Fold module) 420 kg (926 lbs)
Weight of trim module 180 kg (397 lbs)
Weight of ITE 13 kg (28.5 lbs)
Weight of ISF 28 kg (62 lbs)
Weight of delivery conveyor 34 kg (75 lbs)
Electrical / Acoustic
Power supply 120V ±10%, 60Hz, 8A
230V ±10%, 50Hz, 5A
Operational mode
Power consumption 1,200 W
Radiant heat 5,700 BTU/hour
Sound level 70 dB
Standby mode
Power consumption 350 W
Radiant heat 2,525 BTU/hour
Stitch Heads
2 Deluxe Stitch Heads

2 Deluxe Stitch Heads

BM-e Booklet Maker family (Stitch-Fold) with 2 Deluxe Stitch Heads

4 Deluxe Stitch Heads

4 Deluxe Stitch Heads

BM-e Booklet Maker family (Stitch-Fold) with 4 Deluxe Stitch Heads

2 Hohner Stitch Heads

2 Hohner Stitch Heads

BM-e Booklet Maker family (Stitch-Fold) with 2 Hohner Stitch Heads

4 Hohner Stitch Heads

4 Hohner Stitch Heads

BM-e Booklet Maker family (Stitch-Fold) with 4 Hohner Stitch Heads

Stitch Heads Accessories
Quick changeover kit to get 2 Hohner loopstitch heads on BM-e

Quick changeover kit to get 2 Hohner loopstitch heads on BM-e

(this kit includes 2 heads with loop configuration)

BM-e Bourg Kit to upgrade BM-e 2 regular Hohner heads to loop stitch configuration

BM-e Bourg Kit to upgrade BM-e 2 regular Hohner heads to loop stitch configuration

(this kit does not include heads)

BM-e Bourg Kit to upgrade BM-e 4 regular Hohner heads to loop stitch configuration

BM-e Bourg Kit to upgrade BM-e 4 regular Hohner heads to loop stitch configuration

(this kit does not include heads)

Docking DFA
Docking Plate for In-line BM-e 2 Dir

Docking Plate for In-line BM-e 2 Dir

Docking Plate for In-line BM-e 2 Dir

Docking Plate 1020 mm for BM-e / BDF-e

Docking plate between edge registered high output Xerox printer (DocuTech, DS5000) and BM-e / BDF-e

First Aid Kits
BM-e First Aid Kit

BM-e First Aid Kit

BM-e First Aid Kit

Additional Options

BM-e air assit kit digital paper booster

BM-e air assit kit digital paper booster

Bourg Box Communication Interface

Bourg Box Communication Interface

Bourg Box Communication Interface

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This In-Line Bourg booklet making solution with the Océ i300 digital press pays for itself within 2.5 years. Everything is more efficient. It takes us less time to get work out of the door and the end results look great.

John DerBoghossian, CEO

Camelot

New York, United States

At the beginning of the digital era, we were probably a bit behind in investing, admits Thorne, adding: we didn’t want to buy a finishing unit on the back of a digital press, because we wanted something that was a little bit more independent, something we could use with our litho work.

We thought when we bought the Boyurg Booklet Maker BM-e In-Line with the Bourg Suction Tower BST-e, when someone put a 5000-run job through, ‘hang on a minute, we can’t do this’ and we did it—now we’re up to 20,000 runs. We just do it, and it works.

There’s been talk of buying another one. If we did, it would certainly be another C.P. Bourg.

Tim Thorne, Production Director

Taylor Brothers

United Kingdom

We wanted to increase our capacity. We had small machines from competing manufacturers In-Line and Off-Line. The volumes, settings, and capacities did not provide the required production speeds. The C.P. Bourg booklet-making equipment (BSF + BCM-e + BM-e + SQE) allows us to speed up our post-printing production. We've gained in speed (higher production capacity) and quality. The C.P. Bourg machines are really intuitive and easy to manage.

We’ve also gained in productivity: we load the stacks of paper from the carts into the BSF sheet feeder. There’s no more manual work involved in producing brochures now. Everything’s automatic - it’s a great advantage. It means that we’ve doubled and nearly tripled our daily capacity. And this in turn means that our staff can work comfortably at a speed that wasn’t possible with the old equipment.

Thanks to C.P. Bourg booklet-making (BSF + BCM-e + BM-e + SQE), all digitally-printed short runs are handled in house. This guarantees that more work is done in house and all the files are managed upstream. So we ourselves deliver to the clients, which enables us to check the quality of the work done, and to make sure the clients are pleased with the result. In other words, the whole production process is controlled from start to finish.

Our old booklet-maker from a competing manufacturer could only handle 3,000 or at most 5,000 booklets an hour. It was really holding back production. With the C.P. Bourg booklet-maker, we’ve taken a big step forward.

This solution adapts to our production flow: this booklet-maker allows us to handle both digital and offset work, and even both together. This is why we also acquired collators. It means that we can produce the covers digitally with the inside done in offset. Result - a fine, square-edged booklet. This booklet-making solution gives us all the flexibility we need for our production method. We are delighted with it! Because the Bourg Sheet Feeder is so easy to load, our production capacity has been almost tripled.

Hervé Veinguertener, Production Manager

Copiver

France

During the tender, we tested different solutions from competitor’s brands. The Bourg Booklet Making was the most adapted to our needs: the most productive solution, the fastest and the most intuitive which enables the operator to be more versatile.

The Bourg Sheet Feeder (BSF) enables several presses to work with a single booklet making solution. We have a production capacity which suits to our digital presses.

The Bourg Booklet Making solution BSF + BCM-e + BM-e + SQE offers numerous advantages: (1) This system is more intuitive and easier to use. Everything is programmed via the touchscreen. It is a solution which pleased printing agents. They became versatile on printing and finishing systems; (2) it uses less operator time: it frees them up time to concentrate on other tasks; (3) Before, with thicker books, we had to use hotmelt perfect binding or spiral binding. It was more expensive and took more time. Now, we offer precise and good quality stitched square back books; (4) We reduced by half the time taken for finishing which initially took three days. Delivery time has considerably been reduced. In addition, this Bourg booklet making system enables production of smaller formats, variable data and thicker books.

Bernard Besson, technical manager of digital printing service

Les Aéroports de Paris

France

With the traditional offset gathering lines, we could only do one print at a time. We had to wait for the end of the printing before collating. With the C.P. Bourg BSF In-Line with the C.P. Bourg BM-e, we produce on demand. The job is digitally printed, saddle-stitched, trimmed and packed. We have no loss of time. We doubled our production capacity. It’s awesome!

As the alignment is extremely fast and accurate, the BM-e allows making 3-4 copies, as well as 10-12 000 or 20 000 copies of 1, 4 or up to 30 sheets.

Another advantage is that the BM-e makes no scratching and no mark. When a famous cosmetics maker asks you to make a short-run of laminated brochures on a black gold paper, which costs a fortune per unit, you simply have no room for error.

Finally, thanks to this booklet-making solution BSF + BM-e, we met two new demands: (1) The ability to produce of small newspapers in 30 minutes. It was impossible before. Our courier could not leave at 8 o’clock when we received the files at 7:30 a.m. Nowadays, we fill the motorbike trunk as we required. It is very quick. (2) The ability to produce car maintenance log books, which are 42 cm (16.53 in) long but only 10, 5 cm (4.13 in) high. It is the only booklet making module on the market which does that. Even in manual mode, the log books are quickly saddle-stitched. It gives us an advantage over the competition.

Vincent Garnier, Production Manager

AB Printed

France

We produce short-run magazines, mainly in runs from one to 500, both saddle-stitched on the BM-e bookletmaker, or as PUR-bound books on the BB3002-C. Both machines are foolproof and won’t let you do something that could potentially damage them.

If you are looking for a short-run PUR binder you won’t go far wrong with this machine as well as the bookletmaker. In my opinion they are market leaders.

 

Karl Gater, Operations Director

Pensord Press

United Kingdom

Thanks to the Bourg Booklet Maker solution (i.e., BSF + BM-e + BCM-e) working In-Line with the Xerox iGen printer, Print Bound has dramatically cut the cost to produce a booklet. It eliminates make ready-time and printed paper waste to increase efficiency on short runs.

Furthermore, printers can use Print Bound’s capabilities to produce the personalised brochures without investing in new kit they may only use occasionally.

Naresh Gulati, chief executive of parent company OCA

Print Bound

Australia

To complement the new Heidelberg Linoprint CP digital press (OEM’d version of the 130ppm Ricoh Pro C9110), Pensord has ordered a C.P. Bourg BB3002 PUR-C perfect binder, Bourg Sheet Feeder (BSF) with In-Line Bourg Bleed Crease Module (BCM-e) and Bourg Booklet Maker (BM-e), all supplied by UK agent Integra.

"Again we looked at all the main players, but I just liked the build quality, engineering and simplicity of the Bourg machines, the compact adhesive system from Nordson on the binder was particularly impressive", said Karl Gater, Operations Director at £13m-turnover Pensord.

Karl Gater, Operations Director

Pensord

United Kingdom

We bought the Ferrari of digital printing (i.e., HP Indigo 5600 Digital Press) and finishing equipment (i.e., In-Line Bourg finishing equipments: BSF + BCM-e + BM-e + SQE) and it performs accordingly. Our new approach is bringing our entire business to the next level. With it, we’re winning additional work for our printing services and green screen technology segments and new contracts for Green Apple Studios. And if our volume grows higher than expected, we know the HP and Bourg equipment can handle it.

Our booklets are much more exciting than loose-leaf portrait sell-sheets and they have a longer shelf life. They commonly end up on kitchen tables and coffee tables where they can inspire parents and grandparents to see the range of possibilities and place additional orders for prints, calendars and other products.

From an equipment standpoint, we had to learn a lot about digital printing and finishing in a short time. But HP and Bourg provided solid training and support. Plus their equipment’s ease of use and high level of automation also made for short learning curves, allowing us to come up to speed on digital production methods fairly quickly.

Robert Ste-Marie, president

36Pix

Canada

The only difference between finishing digital and offset print output, is that customers often want digital print jobs the same day – an issue that poses no problem for the BM-e. We can interrupt any job and save it in memory, start another job and have it finished and out the door in 30 minutes, and resume the first job all without a hitch.

What is great about the Bourg BM-e, is that it combines the freedom of using largest format size available with more control and more automation. Now we’re able to bid on bigger and more complex jobs – including landscape-format booklets up to 120 pages 11-1/2” x 13-1/2 inches finished dimension.

Mike Hammond, co-owner

Basin Printing & Imaging

Colorado, United States

Thanks to the BM-e and the BST-e, now we can run a wider variety of jobs, including some we couldn’t run on our conventional 6-pocket finisher without getting the new folder. And the work the Bourg system produces is top-notch.

I knew the Bourg BM-e and BST-e were going to be great, but they’re even better than I expected. They’ve allowed us to do more work than we anticipated or were planning on, and utilization has been very high right from the start.

Dave Allan, owner of Allan Graphics

Allan Graphics

Canada

For invitations, we want the fold to be just right, so we use the BM-e to fold the stock, and to do a face trim. The BM-e usually applies just the right amount of pressure, and it allows us to adjust it as well. So the cards come out perfectly.

Michael Habingreither

Bill's Printing Services

Pennsylvania, United States

At the end of the day, any job we don’t have to package and ship off to another bindery where we would be slotted into somebody else’s schedule, we save a customer and we make money. So we make sure we have the best tools for our employees to provide the services our customers want and need, and not just on time, but ahead of time.

The new Bourg BM-e is worth the investment alone in the better control we get over the finishing process. Plus it opens new doors for our business, and once people are aware of what it can do, the financial ROI will follow.

Raj Nadrajan, Director of the In-plant print & finishing department

University of Vancouver

Canada

The pressman knows his equipment like the back of his hand, and the bindery operator has his own expertise. By keeping the two processes physically separate, the operators can collaborate, but no component gets in the way of the other. The presses can run at their full speed, the Bourg production line (BSF + BCM-e + BM-e) can run at its full speed and we have the freedom to take on a greater variety of work, including capacity overflow from other printers.

Before we got the Bourg BSF line (BSF + BCM-e + BM-e), we would fold everything, gather it, put it on a handstitcher, and take it to a cutter for three-sided trimming. The BSF Sheet Feeder with the BCM-e module and BM-e Booklet Maker eliminates all that extra labor and time. And it's amazingly consistent. When a customer places an order at the ZenPrint website, it just blows through our system. Because the entire line is so automated and operator-friendly, once the job is set up at the BM-e Booklet Maker and collated page sets and covers are brought to the sheet feeder on stacking carts, the operator can literally walk away and work on other tasks.

There are other sheet feeders on the market, but nothing as automated, operator-friendly, as well made or designed to operate so seamlessly as the Bourg BSF line.

Plus the work it produces just looks more solid – more professional – and the entire line has a smaller footprint, despite its larger sheet format.

All in all, the Bourg BSF production line has just been awesome, and we couldn't be happier with C.P. Bourg.

Justin Erskine, Director of Production and Fulfillment Services

ZenPrint - Internet book publisher Heritage Makers

Utah, United States