Aayra Production, a Haryana-based print service provider, has maintained a record in the book printing sector—100% client retention with no quality issues.
Operating out of a spacious 18,000-square-foot facility in Sonepat, the company’s 70-member team handles a portfolio spanning educational titles, commercial print, wire binding, hard-case binding, and specialized passport binding.
To maintain strict quality benchmarks without disrupting day-to-day operations, the company has equipped itself with Bindwel’s post-press technology.
Prior to upgrading its post-press setup, the press floor faced recurring operational bottlenecks. Aging imported binding machinery suffered from frequent mechanical breakdowns, long production delays, and inconsistent output.
Poor spare-part availability and reliance on local third-party mechanics further compounded the situation. To eliminate these uncertainties, protect its reputation, and up production, Aayra Production sought a modern, Indian binding solution with direct manufacturer support.
To resolve these challenges, promoter Sameer Popli invested in Bindwel’s post-press solution, the Bindwel 6-Clamp Perfect Binder. It was installed approximately two years ago.
“The machine stood out against alternative options due to Bindwel’s indigenous manufacturing, ready availability of spare parts, and dependable technical support structure. The investment shifted our facility away from high-maintenance imported units to a supported domestic machinery platform. The integration of the Bindwel 6 Clamp binder transformed the post-press workflow,” Popli said.
Equipped with an intuitive touchscreen interface, the system simplified operator training, allowing shop-floor staff to adapt quickly without extended learning curves. A key operational feature is the system’s adhesive coating control (ACC), which precisely regulates glue application during binding.
This targeted technology has reduced adhesive consumption, minimized cover and book material wastage, and strengthened overall page binding integrity across varied paper. The company commonly works with Maplitho paper, coated paper and other publishing papers, typically ranging from 52 gsm to 120 gsm, depending on the application.
Today, Aayra Production runs an end-to-end in-house print and post-press operation, transitioning signatures from 2-color and 4-color Heidelberg offset presses through folding, gathering, section sewing, perfect binding, and three-knife trimming. Shift metrics reflect substantial capacity gains, with the shop floor now producing up to 18,000 books in a single 12-hour shift while maintaining low downtime.
The company’s post-press portfolio consists of a Brehmer folding machine, 24-station Polygraph gathering machine, five Polygraph section sewing machines, Bindwel perfect binder, Muller Martini Amigo perfect binder, Wohlenberg three-knife trimmer.
The real-world test of this updated workflow arrived with a major international export contract — producing 100,000 books for a client in Poland. Executed on the Bindwel setup, the project was delivered with near-zero quality rejections, proving that Indian post-press engineering could meet rigorous international print standards.
Popli says, “Beyond machinery performance, the ongoing technical partnership with Bindwel has provided critical operational security. Technical issues are routinely addressed within a few hours through telephone assistance or rapid on-site engineer visits, ensuring production schedules remain intact.”
Looking ahead, as rising labor expenses and overhead drive the print market toward greater factory efficiency, Aayra Production plans to build on this foundation by expanding its automated manufacturing and post-press capabilities over the next decade.
