Specialised Adhesive Process Machine ("SAP")
Sticky note manufacturing machine
The “SAP” is the only A3 sheet fed ‘Sticky Note’ Machine in the world
This unique, fully automated machine makes it possible for ANY small to medium printer to add this sought after product to its’ product portfolio.
Digital print companies can economically produce the shortest of runs, even producing as few as 16 “personalized” pads! Traditional litho printers can utilize the available rolling power capacity of their existing litho machines, whilst tapping into this lucrative market.
This machine is used by printers who wish to capitalize on a very focused niche market in which there is generally very little competition. At present is by far the smallest and the most affordable repositionable note machine in the world.
How it works
- The artwork is pre-printed onto sheets of SRA3 sized paper. This is the only size paper the machine can use. Standard uncoated paper is used - most commonly bond/cartridge style paper.
- The printing method is not critical. Lito printing, inkjet printing, or laser printing will do equally well.
- Pads can be made in a veriety of different sizes, because the glue strips are adjustable. For example, mouse pad size or smaller, long pads for bookmarks, or small square pads to write on. The standard and most commonly used configuration is 16 up, head-to-head in a fixed impositioned manner. By adjusting the position of the adhesive rollers, pads of different sizes can be made on the same sheet.
- Any paper will work as long as the glue will adhere to its surface, and provided that the paper thickness is not too heavy. 80 - 100 gsm bond-style paper is most commonly used. Even photocopy paper is suitable. The process is also very effective on card material. The most critical provision is that only long grain paper may be used.
- The machine's counter is now set to the desired quantity of sheets in the pad. For example, if you wish to produce pads containing 25 sheets each, the counter is set to 25.
- The sheets are then automatically fed through the machine, during which they are coated by a micro thin layer of glue, using a gravure roller system.
- Next the sheets are flash dried beneath infra-red lamps.
- The sheets are thus cured and are deposited in the paper output tray or jogging station.
- When 25 sheets have been coated (or whatever number that was set on the counter), the machine will automatically stop.
- The operator can now insert a sheet of backing paper if desired. Backing paper makes the pads look neat and professional. Backing paper or backing board is often printed with the supplier's advertising or logo and contact details, as well as instructions on how to re-order stock. Since the machine is top-loading, bottom-feeding, paper can be added or removed without stopping the machine. The operation is therefore coninuous.
- Once the paper output tray is full the paper can be removed and stacked elsewhere with a light weight placed on top to smooth down any potential curvature.
- When the production batch has been completed the coated stacks can now be cut to size with a guillotine, using the lightest possible clamping pressure. The guillotine's clamping pressure provides the last force that is required to provide the final degree of firmness in the glue adhesion of the pads.
- The same machine can also handle light boards for the production of pre-glued bookmarks. This is the only machine in the world capable of this function. The SAP produces bookmarks that does not fall out of a book, e.g. a Bible, Diaries, Novels etc.
- Because the sheets can be collated before feeding into the machine, variable data processing is possible. In other words, pads that contain sequentially printed material can be produced. This feature is also world-unique to the SAP machine. Examples would be numbered pads, or pads that contain different scriptures or proverbs or jokes on each succeeding pad.
- The glue strips are applied as shown on this template which represents the way the machine is set up by default. Note that the positioning of the glue strips can be adjusted by the operator to accommodate different sizes of pads. The glue strip width can also be adjusted by ordering additional rollers of different widths so that either narrower or wider glue strips are produced.
The following examples will illustrate the endless posibilities that the SAP can offer:
Bookmarks can be made using card stock as backing board up to 250gsm.
Bookmarks are made up in long, slender pads with peel-off sheets.
Bookmarks containing jokes, quotes or sayings of wisdom can be a popular and fun product with a very high profit margin.
Sticky notes can be produced with backing board, if desired.
Sticky notes can be left blank for general use.
Pads can be branded and printed with the customer's own designs.
|| Conventional sticky note machines|
|The only flat-sheet fed sticky note machine in the world.
||Can only use paper in coil form. |
The most inexpensive sticky note machine in the world.
|Usually cost in the order of 20 times more. |
|The SAP is by far the smallest sticky note machine in the world.
||Alternative machines are of enormous size, stretching well over 10 metres or more. |
A wide variety of different paper types can be used.
|In most cases only special pre-glued paper can be used. |
|A wide variety of different printing methods can be used.
||Usually a dedicated web printer is required that can only be used for the sticky notes.|
|Variable data can be used.
||Variable data is not possible.|
|Suitable for on-demand applications.
||Only long production runs are practical.|
|Both small and large production runs can be accommodated.
||Small production runs are not practical.|
|A wide variety of user-determined pad sizes can be accommodated.
||Only pads of the size provided for by the supplier can be manufactured.|
|Practical for small- and medium producers.
||Only practical for large-scale producers.|
Other printed sticky note ideas
- Computer mousepads
- Daily calenders
- Daily scriptures
- A joke a day pads
- Famous quotes pads
- Cartoon pads
- Colouring book pads for children
- Mini jobcards for factories
- Insult pads
- and many, many more...
Frequently Asked Questions
- How does the machine work?
A3 sized sheets of paper are first printed using the technology of your choice. It can be digital or offset, for example. The flat sheets of printed paper are then loaded into the SAP machine. The machine is suction-fed, top loading, bottom feeding. The machine will now coat the sheets with glue strips. The glue is applied using a unique hybrid roller system. The adhesive is water-based so immediately after the adhesive strips have been applied the paper has to be flash dried in a infrared drying tunnel. The rest of the machine is just a standard paper handling system such ascan be found on many printing machines around the wrold. The coated and dried sheets of paper are released into a holding tray which must be periodically emptied. As the paper is emptied, it can be stacked on a work table. A modest weight is placed on top of the stack to maintain firm pressure while the paper goes through a few more minutes of curing. About 15 to 20 minues later the paper can be cut to final size on a guillotine. The final procuts are now ready for use. The machine's paper is loaded and emptied without stopping the machine.
- Where does the adhesive come from?
The adhesive is manufactured in the USA by an internationally known company. The manufacturer has distribution agents in a wide range of the world’s major cities, but the regional agencies are usually only able to supple adhesive in industrial quantities. In most cases customers may be better served by ordering directly from the manufacturer's international distribution agency in the Unites States. The glue is a standard stock item. The glue code is only supplied to the customer when we receive a deposit for an order. The exact source and code is not revealed upon casual enquiry. Please do not request the glue source or product code until a definite order has been placed.
- What does the adhesive cost?
The adhesive cost is low enough that it is usually not included in costing of jobs, as with overhead costs such as electricity, insurance, etc. The cost may vary from country to country but currently costs around US$185 per 5 gallon order, which is the minimum order quantity, ex-factory. Adhesive may also be ordered from the factory in South Africa at R5,500 (South African Rand) per 20 litres, EXW. The exact adhesive consumption rate will vary according to the configuration and design of the glue pattern. At present it is calculated at roughly 0.5 - 1mm of adhesive per A3 sheet. This yields an adhesive cost of around US$0.0087 per SRA3 sheet, or about US$0.000435c per leaf of 75mm x 75mm at current prices.
- Does it work with gloss paper?
This product is not intended for use on gloss paper.
- What kind of paper must be used?
The machines is available in two paper sizes: SRA3 paper (320mm x 450mm), or SRA4 (225mm x 320mm).
A paper thickness of 80-90 gsm is recommended.
Very important: Only long grain paper may be used.
This machine is unique in that it does not require pre-coated paper and no re-lease agents.
Most producers use standard bond/cartridge style paper.
- How thick can the pads be?
There is no specific limitation on the thickness of pads that can be produced. However common sense applies. The adhesive strength is purposefully kept at an optimal balance. If excessively thick pads are made, the weight of the pad can start exceeding the binding strength of the adhesive which causes distortion. The industry average is around 100 sheets per pad maximum. If thicker pads are desired, it is recommended that the manufacturer test first to ensure that the binding integrity will remain acceptable.
- Does the machine have CE registration?
The machine is CE marked and can be imported into EU member countries.
- Can pads of different sizes be made?
Yes. The sizes can be changed by adjusting the glue rollers. Repositioning the glue rollers alters the glue patter so that the operation can yield long narrow sticky notes for bookmarks, or rectangular ones, or square ones - all in different sizes. You can, for example, produce postage stamp-sized pads, or even smaller. You can also produce long narrow ones.
Pads can also be mouse-pad sized, or they can glue entire sheets so that the maximum pad size is A3.
By adjusting the position of the glue rollers you can produce different sized pads on the same sheet. For example, you can make mouse-pad size sticky notes on one length of paper, plus some small sticky notes next to it.
Irregularly-shaped pads (such as hard-shaped pads, for instance) can be made by means of die-cutting, using post-press die-cutting machines that are widely available world-wide. Note that wee do not supply die-cutting equipment. There are many die-cutting solutions that are available around the world, which will do a fine job of producing unique pads of infinite variety.
The machine comes standard with two glue rollers. If more strips are desired, extra rollers can be ordered, but the standard configuration seems to satisfy nearly all customers' needs. Roller width can also be custom ordered, but again, standard size serves most needs.
- Can the position of the glue strips be adjusted?
Yes, the user can adjust the glue strips to different configurations.
- How is the paper glued?
The glue is applied in long parallel strips along the length of oversize A3 sheets of paper. Two separate strips of glue are applied to a sheet so that the pads lie head-to-head. When the paper is cut in-between the two strips of glue, two sets of pads fall away from each other. In other words these sets of pads are separated by cutting in-between the glue strips. This is done twice in the same sheet so that altogether four sets of pads are obtained from one sheet. The glue is instantly dry when it falls out. The stack is then guillotined to final size. The factory standard configuration is for 20 pads of 75mm x 75mm per SRA3 sheet of paper.
- Is installation and commissioning required?
Ideally the machine should be installed and commissioned by a technical engineer. This cost is additional to the purchase price of the machine. We can quote an all-inclusive price if desired. In most cases the customer provides the cost of accommodation and travel, plus a $100 per day allowance. This is nearly always the most economical option.
The buyer can also send a technician for training to the factory in George, South Africa. The technician will be trained to install and commission the machine, and will also be trained in all relevant aspects of support and repair. One business day will be required, as long as time is allowed to recover from travel fatigue.
The third option is self-installation. We are able provide an installation and operation training video which will guide customers to commissioning their own machine. A basic level of technical expertise is required, but anyone who is familiar with the basics of keeping printing presses healthy, should be able to master the task. If additional help is required, guidance by telephone or email is available from the factory at no charge.
- Does it matter what kind of printing is used?
It does not matter how the paper sheets have been printed. Laser or litho printing will, for example, work equally well. The glue is not applied where the paper is printed so it has no effect.
- Is special pre-coated paper or custom printing required?
No. Standard paper printed with standard printing machines will suffice.
- Is variable data production possible?
Yes. Because it is sheet fed, you can make up pads with different colours paper in each pad, or with different printed images on each sheet. All you need to do this is to collate the sheets before feeding through the machine. Industry standard sticky note machines cannot do this, but it is easy with the SAP. This enables the user to produce sticky notes of a kind which can not generally be found in the market. This unique distinguishing feature can unlock the doors to new customer accounts and new revenue streams. Creative applications for variable data content in sticky notes is a very exciting feature of immense value.
- How much labour is required?
The machine requires one full time operator to load and unload paper. If you have more than one machine, you will still need one operator for each machine.
- What paper handling system is used?
The paper system is suction fed, top-loading, bottom feeding. The machine does not have to stop while paper is loaded or unloaded. Production can therefore be continuous.
- How much maintenance is required?
The only routine maintenance involves checking the compressor's oil level. At the end of each day's production, a 20 minute washup process is required to clean the glue trough. This can be done in a regular wash basin using warm water and a little detergent soap. The machine has been designed so that there are no serviceable parts and no scheduled maintenance is required.
- What electrical supply is required?
220-240V single phase, 15 Amp.
- What is the production speed?
About 700 - 800 SRA3 sheets per hour, which yields about 15,000 standard-sized note sheets per hour.
- What setup is involved?
No setup is required. Insert the paper, switch the machine on and production starts immediately. No warmup or calibration is required. In nearly all cases the first sheet should come out ready to use. This results in extremely low wastage.
- What cleanup is required?
The machine uses water-based glue which must not be allowed to dry.
After a production cycle the glue roller unit is removed and washed by hand in cold or mildly warm water, containing a few drops of household liquid detergent.
Alternatively the unit can be left in a container of cold water overnight, to be refitted in the machine the next morning, if desired.
There are no feeder tubes to flush.
- What maintenance is required?
Checking the oil level of the air compressor and keeping the machine clean is the only maintenance that is required. There is no other scheduled maintenance on this machine. Our machines are built with the expectation that they will sometimes be used in countries where limited or no service support infrastructure exists. They are therefore built to be exceptionally long-lasting, durable, and low on maintenance requirements.
- What does the warranty entail?
Unless otherwise provided for by a reseller, the standard international factory warrantee is 6 months on parts only, supplied ex-factory; labour excluded.
- How can spares be obtained?
All products are designed using stock-standard electrical parts that are generally available from practically any good electrical supply outlet in the world.
Relay switches, contactors, UV lamps and other parts are interchangeable with generic equivalents so that it does not matter whether for example, Siemens or some other aftermarket component is used. This is a deliberate design approach in order that products may be self-serviceable even in developing countries with poor service infrastructure which applies to all our machines.
Mechanical parts can all be engineered locally in case of emergency.
All spare parts can at all times be ordered directly from the factory in South Africa.
- What are the dimensions and weight?
The machine is supplied with startup glue stock included, in a wooden crate which is 129cm long, 130cm high and 274cm wide. The weight is appoximately 500kg.
Both air and ocean freight is usually an economical option.
- What will the transport cost be to my country?
We receive many requests for transport quotations, usually from casual enquiries from unqualified buyers. Shipping estimates are always referred to logistics companies. We would typically use Morgan Cargo or Hellmann Logistics. You will receive faster service and lower prices by requesting your shipping quotes directly. You can also use any other logistics company of your choice.
Suggestions for requesting a shipping quote may be obtained here.
- How do I import a SAP into my country?
Shipping and freight logistics companies are usually extremely helpful in assisting buyers to import machines. Your local logistics company will nearly always offer the best terms. They will need the dimentions above, plus the invoice price. Provide these details and they should be able to take care of the details.
- Do you have branches in other countries?
Not at the moment. All sales and communication is directly from the factory in George, South Africa.
- Can I become your international sales agent?
In order to benefit from wholesale prices, a minimum of two SAP machines must be ordered at a time, and a minimum sales performance level must be maintained. You must already be a dedicated machine merchant that serves the printing industry. If your company can meet these conditions please feel free to contuct us to discuss options.
- How can I obtain samples?
We receive a large number of sample requests every month, often out of mere curiosity. If you wish to requests samples, please send your request by email.
There are two options:
(a) We can provide a small sample set will be sent by standard air mail. This will take at least 10 - 21 days to arrive. Please make sure that you provide your correct postal address and full contact details.
(b) If you are in a hurry, you may instruct your own couriers to collect. In this case, please confirm the collection date with us first and provide an accurate physical delivery address with telephone number and full contact details.
If you wish to have your own sample material processed you may send your samples to us, after which you will be notified when you can send your courier to collect. Please allow generous time for this because samples can only be made at the end of a manufacturing cycle when finished machines are available.
If you wish to receive sheets of samples that are glued but not cut into pads, please specify clearly, arrange own courier transport and allow extra time. When the samples are ready you will be notified for your couriers to collect.
- How does the ordering process work?
The process normally starts with a customer requesting a price ist.
Once he has satisfied himself with the price, a formal quotation or Proforma Invoice may be requested. Please do not request a Proforma Invoice unless you are making an actual purchase, as a Proforma Invoice is regarded as a financial transaction that should be honoured.
Now review the Proforma Invoice for completion and accuracy. It is important that the customer's full contact detail be shown on the Proforma as this document will form the basis from which all the shipping documents will be drafted.
The customer then submits the Proforma Invoice to his bank, requesting a SWIFT international wire transfer to be made to our bank, for a deposit of 50% of the invoice value.
When the funds have cleared the customer is issued a Commercial Invoice which is an identical copy of the Proforma, except that the machine's serial number will not be indicated on the document.
Manufacturing then commences.
When the machine is completed the customer will be contacted to request payment of the balance. At this time the customer normally has the option of viewing the machine in our factory before it ships and receiving installation and operating training if required.
After that, the customer is notified of a date that the machine will be ready for collection. Contacting an international freight forwarding company will take care of all the details. Once they have quoted the buyer, they will usually contact us directly so that the logistics can be arranged.
At his point the machine will be shipped to its destination. If factory installation and operational training is required, this will be the time to arrange a visit with a factory engineer.
- What is the lead time and payment terms?
Products are manufactured on order. Payment is 50% payment at order, the balance before shipment. Lead time is 6 weeks from acceptance of order.
- What is the price of the machine?
The current retail price is US$28,000 ex-works. Shipping is not included.
Click here to download a presentation-style document which illustrates the business potential and opportunities for the Powerbind SAP (5MB).
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