Edwards Brothers Malloy has three offset printing facilities. Our Jackson Road facility was built in 1960 and founded as Malloy Lithographing. Today it has grown to more than 180,000 square feet and features some of the most advanced book manufacturing equipment our company has at its disposal.
First we will take a look at our automated plate-making line. Added in 2005, the plate room is one of the first fully automated plate making lines to be installed at a book printer in North America. Two redundant lines cover over two thousand square feet of floor space. 3 plate setters and 4 imaging heads produce 12 to 15 thousand aluminum printing plates per month. The system is designed for Just in time processing allowing Edwards Brothers Malloy to start customer jobs quickly. It takes just six minutes for the first plate to be produced from start to finish and two additional minutes per plate after that. The entire system can be run with just one operator per shift.
Next we’ll take a look at two of our cutting edge offset web presses. Our Jackson Road plant was the first facility to purchase a Timsons web press back in 1982. We now have 8 timsons web presses at this location and our company as a whole has the largest fleet of Timsons in North America. Installed in early 2006, this Zero make ready machine known as T8 can print at top speeds of about 1300 feet of paper per minute. It occupies roughly 4,050 square feet and is capable of printing one and two color jobs. The addition of folder and palletizer make this press fully automated.
A sister to T8 and occupying roughly 3,600 square feet is T7. Timson number 7 is similar to T8 however it accommodates a slightly smaller paper size. An entire addition to the building was added specifically for this machine. It is also fully automated reducing the workload and manpower needed to produce jobs in a matter of minutes. T7 and T8 are some of the most advanced web presses in our equipment line up and make printing large quantities of books incredibly cost effective for customers.
We also use sheet fed presses for making books. Installed in 2008, the HA cover press uses Heidleburg anicolor technology to render stunning color and detail for book covers. There are three sheet fed presses at the Jackson Road facility.
One of our 11 digital book centers located throughout the world is located here at the Jackson Road Facility. This location features imaging units from OCE (oh-say) to produce printed pages and covers. Our minimum run for softcover books at this facility is 24 copies and 100 copies for a hardcover book. Books printed in any of our digital book centers do not need to conform to specific trim sizes. This enables us to use the most cost effective equipment—offset or digital—that our customers need to meet the demand for their books. No need to monkey around with trim sizes based on whether you need thousands or only dozens of copies at a time. Our digital books centers help publishers and content creators keep their inventory levels under control.
We use a film laminator and 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 printed paper at about 180 ft per minute. The UV coater applies a thin layer of ultra violet protection to covers at about 6,000 sheets an hour. These two machines exemplify of how Edwards Brothers Malloy provides high quality products at low cost to its publishers.
Now let’s take a look at the Bindery. Three binders take up over 19 thousand square feet in the back of this facility. Binder 2 is the most highly automated of the three. Added in 2002, binder 2 sports a collator with 14 feeders and can produce out about thirteen thousand book blocks per hour at top speed. Binder 2 feeds a brand new state of the art trimmer built by Mueller Martini. The trimmer operates at 6000 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 Diamant case line. Added in the spring of 2011, the case line is capable of churning out 35 case bound books per minute. The addition of a Vesta inline jacketing machine allows dust jackets to be added to finished books as they leave the line. The new case line is just one in a series of investments that Edwards Brothers Malloy has made to offer lower cost and higher quality services to publishers.
Edwards Brothers Malloy handles storage and fulfillment for many of its customers. 18 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 air screen filtration system. First installed in 1993 and upgraded in early 2004, the filtration system collects more than 2 and a half tons of scrap paper each day and shoots it through 2500 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 design scrap retrieval system is an integral part of a comprehensive recycling program that earned the Jackson Road facility zero land fill status in September of 2009. No manufacturing waste is sent from this facility to a landfill.
The cornerstone of our operation is not a piece of equipment or any of our facilities, it is the team of customer service professionals who help publisher manage their titles printing at Edwards Brothers Malloy. Our CSR’s have been with the company for an average of over 20 years. Their extensive experience and knowledge gives them the ability to truly make our customer’s jobs easier.