PRODUCTION DESCRIPTION

The Right Size Stitching Wire for the Job:

The majority of the stitching wire used in today’s binderies and in-line stitching operations is 24 and 25 gauge. The difference in size from 24 Gauge (.023”) to 25 gauge (.0204”) is .0026”. This small amount may seem insignificant, but means a lot in terms of yield.

A 24 Gauge wire has 8,496 inches per pound of wire and 25 Gauge has 10,800 inches per pound. This amounts to a 21.3% difference in product yield, which translates into 21.3% more staples if you use 25 Gauge over 24 Gauge. In simpler terms if you imagine a staple or stitch being 1 inch, you would have 2,304 more staples by using the 25 Gauge wire over 24 Gauge

Choose the right wire for the job.

25 gauge stitching wire’s recommended thickness of work is 1/16 to 7/32 of an inch

24 gauge stitching wire’s recommended thickness of work is 1/16 – ¼ of an inch

These are only suggestions as paper type, density, coatings, and stitcher set up can change the stitching wire size required.

Physically check the size of your stitching wire and don’t believe what is on the label until you are sure. An oversized wire that is labeled 25 gauge but is actually larger in size means you are not getting what you are paying for.

Oversized wire substantially affects the yield of your wire along with increasing the amount you end up paying at the post office in postage.

Spool Sizes and De-Spooling Equipment:

Stitching wire comes on many different spools and generally range from 5 lbs to 1600 lbs in size. Primary usage and machine type determines the size spool you require, but running speeds and space availability also play a role. Stand alone stitchers that are hand fed usually use 5 or 10 lb spools. Collators with stitchers used for short runs of 5 to 10,000 books can also use this type of spool. Saddle stitching longer, mid-range runs will use 35, 40, 70, or 100 lb spools. High speed saddles stitchers, and web operations using in-line stitchers will use 200, 250, 1,000, and 1600 lb spools. A larger spool of wire has both economical and production advantages. Larger spools cost less per pound of stitching wire to manufacture. Larger spools require fewer spool changes during the manufacturing process.

Different size spools have different characteristics that can give the end user advantages. For instance, as stated earlier, a larger circle diameter improves the performance of stitching heads with less friction due to less straightening required and fewer dropped stitches. The larger diameter spools such as the 200, 250, 1,000 and 1600 lb spools have larger circle diameters improving stitcher head performance since less straightening is required.

Proper de-spooling equipment is essential to compliment the high quality wire you use. Matching the correct de-spooler with the spool is essential to problem free production.