Machine Model: Challenger-5000 Perfect Binding Line (Full Line)
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Machine Model: Challenger-5000 Perfect Binding Line (Full Line)
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| Items |
Standard Configurations |
Q‘ty |
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| a. | G460P/12Stations Gatherer | Including 12 gathering stations, a hand feeding station, a criss-cross delivery and a reject-gate for faulty signature. |
1 Set |
| b. | Challenger-5000 Binder | Including a touch screen control panel, 15 book clamps, 2 milling stations, a moveable spine gluing station and a moveable side gluing station, a stream cover feeding station, a nipping station and automatic lubrication system. |
1 Set |
| c. | Supertrimmer-100 Three-Knife Trimmer | Including touch screen control panel, horizontal in-feed carriage belt from the right, vertical in-feed unit, three-knife trimmer unit, gripper delivery, and discharge conveyor. |
1 Set |
| d. | SE-4 Book Stacker | Including stacking unit, book pushing unit and emergency exit. |
1 Set |
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e. |
Conveyor |
Including 20-meter connection conveyor. |
1 Set |
The Challenger-5000 Binding System is an ideal binding solution for small to medium production runs with max. speed up to 5,000 cycles per hour. It featurs operational convenience, high productivity, flexible changeover for multiple binding methods, and excellent performance ratio.
Outstanding Features:
♦High net output at 5000 books/hour with thickness up to 50mm.
♦Position indicators provide user-friendly operation and precise adjustments.
♦Spine preparation with powerful milling motor for top-quality spine forming.
♦Rigid nipping and cover scoring stations for strong and accurate binding.
♦European imported spare parts gurantee strong and consistent performance.
♦Flexible changeover between hotmelt EVA and PUR binding method.
Configuration 1: G460P/12 Stations Gatherer
G460P gathering system is speedy, stable, convenient, efficient, and flexible. It can be used either as a stand-alone machine or connected in-line with Superbinder-7000M/ Challenger-5000 Perfect Binder.
●Reliable and non-marking signature separation thanks to the vertical gathering design.
●Touch screen allows easy operation and convenient fault analysis.
●Comprehensive quality control for miss-feed, double-feed and paper jams.
●Easy changeover between 1:1 and 1:2 production modes brings high flexibility.
●Criss-cross delivery unit and hand feeding station are offered as standard features.
●Reject gate for faulty signatures ensures non-stop production.
●Excellent quality control is enabled by the optional signature recognition system.
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Touch Screen Control System The touch screen control system allows easy operation and convenient fault analysis.
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12 Gathering Stations 4 station as 1 unit, totally 3 units.
Automatic signature inspection system on each gathering station to detect miss-feed, multi-feed, and paper jams (there is a sensor on each gathering station to detect miss-feed, and there is a proximity switch on each gathering station to detect multi-feed, in order to guarantee the thickness is correct).
The vertical gathering design can reduce the friction of signatures so as to avoid any mark on the paper during gathering process.
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1:2 Speed Mode Change Mechanism High gathering speed with 1:2 speed change mechanism.
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Reject GateThe reject gate for faulty signature ensures a non-stop production. |
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Hand Feeding Station Hand feeding station is provided for convenient feeding of additional signatures. |
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Criss-Cross Delivery UnitThe criss-cross delivery unit is provided for efficient collection of well-gathered book blocks. |
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Orion Vacuum Pumps1 vacuum pump for each unit, totally 3 vacuum pumps for G460P/12 stations |
Configuration 2: Challenger-5000 Binder
The 15-clamp perfect binder Challenger-5000 is an ideal choice for small to medium production runs with speed up to 5000 cycles/hour. It features easy operation and precise change-over by position indicators.
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A control station with touch screen displayInteractive operating menu provides simple and quick control of the machine. Production data, machine speed and alarm message are displayed. |
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An inclined infeed stationInclined infeed station includes connection with G460B gatherer (available for hand-feeding). The leveling table with integrated vibrator guarantees that all signatures are perfectly alligned before spine preparation. |
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15 sets of book clampsOpening width of all clamps adjusted at a time and displayed by position indicator.
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Two spine milling stationsTwo spine preparation station provides for milling and notching, which makes sure that the spines are optimally prepared for glue application.
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A moveable spine gluing stationThe moveable EVA spine gluing station with pre-melter acts as an interchangeable system for PUR application.
A moveable side gluing station The moveable EVA side gluing station with pre-melter acts as an interchangeable system for PUR application. |
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A stream cover feeding stationThe flat infeed design allows large production load to be produced stably and comfortably.
Cover scoring wheels can be adjusted conveniently according to the book thickness and cover format.
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A nipping stationA superior nipping system exerts powerful nipping pressure to create strong, durable binds with sharp spine corners. |
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A declined delivery unitSmooth lay-down device prevents the spine from deformation and acts as an interface for inline connection. |
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A paper dust extractorPaper waste can be removed by the powerful paper dust extractor to keep the system clean. |
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An automatic lubrication system |
Configuration 3: Supertrimmer-100 Three-Knife Trimmer
The Supertrimmer-100 features sturdy configurations and precise cutting accuracy with a user-friendly touch-screen control panel. This machine could be used stand alone, or connected in-line for a complete binding solution.
♦Streamlined process: feeding, positioning, pushing-in, pressing, trimming, output.
♦No book no cut control to avoid unnecessary movements
♦Cast-made machine frame for a reduced vibration and higher trimming precision.
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One set of Supertrimmer-100 Touch screen control panelHorizontal infeed carriage belt from the right
Vertical infeed unit Three-knife trimmer unit Gripper delivery Output conveyor
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Configuration 4: SE-4 Book Stacker
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One set of SE-4 Book Stacker Stacking Unit. Book Emergency Exit. |
Configuration 5: Conveyor
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20-meter connection conveyorTotal length: 20 meters.1 book emergency exit.
LCD main control. Each section of conveyor speed adjusted by ratio or separately.
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Critical Parts List of Challenger-5000 Binding System |
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Item no. |
Parts Name |
Brand |
Remark |
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1 |
PLC |
Schneider (French) |
Gatherer, Binder, Trimmer |
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2 |
Inverter |
Schneider (French) |
Gatherer, Binder, Trimmer |
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3 |
Touch Screen |
Schneider (French) |
Gatherer, Binder, Trimmer |
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4 |
Power supply switch |
Schneider (French) |
Binder, Trimmer |
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5 |
Power supply switch |
MOELLER (Germany) |
Gatherer |
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6 |
Main motor of binder, Milling station motor |
SIEMENS (Sino- Germany joint venture) |
Binder |
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7 |
Switching power supply |
Schneider (French) |
Gatherer |
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8 |
Switching power supply
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East (Sino-Japanese joint venture) |
Trimmer |
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9 |
Photoelectric switch
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LEUZE (Germany)， P+F(Germany)， OPTEX (Japan) |
Gatherer, Binder |
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10 |
Proximity switch |
P+F(Germany) |
Gatherer, Binder, Trimmer |
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11 |
Safety switch |
Schneider (French)， Bornstein(Germany) |
Gatherer, Binder, Trimmer |
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12 |
Buttons
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Schneider (French)， MOELLER (Germany) |
Gatherer, Binder, Trimmer |
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13 |
Contactor |
Schneider (French) |
Gatherer, Binder, Trimmer |
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14 |
Motor protection switch, circuit breaker |
Schneider (French) |
Gatherer, Binder, Trimmer |
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15 |
Air pump
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ORION (Sino-Japanese joint venture) |
Gatherer, Binder |
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16 |
Air compressor
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HATACHI (Sino-Japanese joint venture) |
Full Line |
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17 |
Bearing
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NSK/NTN (Japan), FAG (Germany), INA (Germany) |
Binder, Trimmer |
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18 |
Chain
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TSUBAKI(Japan), TYC(Taiwan) |
Binder, Trimmer |
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19 |
Electromagnetic valve
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ASCA (USA), MAC (Japan)， CKD (Japan) |
Gatherer, Binder |
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20 |
Air cylinder |
CKD (Japan) |
Gatherer, Trimmer |
Remark: The machine design and specifications are subject to change without notice.
| Technical Data | |||||||||
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Machine Model |
G460P/8 |
G460P/12 |
G460P/16 |
G460P/20 |
G460P/24 |
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| No. of Stations |
8 |
12 |
16 |
20 |
24 |
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| Min. Sheet Size (a) |
196-460mm |
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| Min. Sheet Size (b) |
135-280mm |
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| In-line Max. Speed |
8000 cycles/h |
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| Off-line Max. Speed |
4800 cycles/h |
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| Power Required |
7.5kw |
9.7kw |
11.9kw |
14.1kw |
16.3kw |
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| Machine Weight |
3000kg |
3500kg |
4000kg |
4500kg |
5000kg |
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| Length of Machine |
1073mm |
13022mm |
15308mm |
17594mm |
19886mm |
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Machine Model |
Challenger-5000 |
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No. of Clamps |
15 |
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Max. Mechanical Speed |
5000 cycles/h |
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| Book Block Length (a) |
140-460mm |
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| Book Block Width (b) |
120-270mm |
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| Book Block Thickness (c) |
3-50mm |
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| Cover Length (d) |
140-470mm |
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| Cover Width (e) |
250-640mm |
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| Power Required |
55kw |
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| Machine Model |
Supertrimmer-100 |
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| Untrimmed Book Size (a*b) |
Max. 445*310mm (Off-line) |
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Min. 85*100mm (Off-line) |
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Max. 420*285mm (In-line) |
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Min. 150*100mm (In-line) |
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| Trimmed Book Size (a*b) |
Max. 440*300mm (Off-line) |
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Min. 85*95 mm (Off-line) |
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Max. 415*280mm (In-line) |
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Min. 145*95mm (In-line) |
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| Trim Thickness |
Max. 100 mm |
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Min. 10 mm |
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| Mechanical Speed | 15-45 cycles/h | ||||||||
| Power Required | 6.45 kw | ||||||||
| Machine Weight | 4,100 kgs | ||||||||
