For Aayra Production, book binding is not a new part of the business. The Sonipat, Haryana-based company has been working in book printing and binding for 35 years. Sameer Popli, Owner of Aayra Production, represents the third generation of the family business.
Before installing the Bindwel BW@2500 in 2024, Aayra Production was using imported binding machinery, including German machines from the early 2000s. Over time, spare-part availability became a major concern, while Sameer says the older machines were not delivering the quality and speed the company expected.
The move to a new perfect binder for book printing was therefore driven by practical production requirements: better quality, higher output, reduced breakdown time, easier operation and dependable service support.
Aayra Production’s Book Printing and Binding Operations
Aayra Production has been involved in book printing and binding for three decades and operates from Sonipat, Haryana.
The company had previously relied entirely on imported binding machinery. According to Sameer, some of the machines were German imports from the early 2000s. As these machines aged, finding original spare parts became increasingly difficult.
The problem was not limited to sourcing components. Sameer explains that Aayra sometimes had to bypass certain machine functions to keep production running. This could then contribute to further breakdowns.
For a book printer, such interruptions can have a direct impact on production schedules. A binding machine needs to deliver consistent output while remaining practical to operate and maintain.
That was the situation in which Aayra Production began looking for a new binding solution.
Why Aayra Production Chose Bindwel
For Aayra Production, local manufacturing and service support were important factors in choosing Bindwel.
Sameer points specifically to Bindwel’s manufacturing facility in Bangalore and the fact that the machines are made in India. This was particularly relevant after the company’s experience with older imported equipment and the difficulty of sourcing spare parts.
The decision was also based on the quality of the machine. Sameer says that although the pricing was competitive, Aayra Production was happy with the quality of the Bindwel machine.
For a perfect binder for book printing, the investment is not simply about machine capacity. Availability of technical support, ease of operation, maintenance and the ability to maintain book quality are all part of the production equation.
What Changed After Installing the Bindwel BW@2500?
According to Sameer, Aayra Production saw improvements in both production quality and speed after the Bindwel machine was installed.
The company also experienced reduced breakdown time compared with its previous machinery. Sameer identifies this as an important change because breakdowns had been one of the problems associated with the older machines.
The BW@2500 also brought changes in the way operators interact with the binding process. The touchscreen control panel allows operators to understand machine errors and view production information, according to Sameer.
For Aayra Production, this makes the machine easier to use and simplifies operator training.
Adhesive Coating Control and Material Usage
One of the features Sameer highlights most strongly is ACC, or Adhesive Coating Control.
He explains that the previous process involved a thicker glue coating than was required. With the BW@2500, he says the machine provides the amount of adhesive coating required for the book and its required strength.
This has been important for Aayra Production because adhesive usage is directly connected to material consumption and the finished spine.
Sameer says the machine has helped reduce raw-material wastage and that the resulting spine comes out better compared with the machine previously used.
For a perfect binder for book printing, adhesive application is an important part of the finished-book process. Consistent adhesive application can affect both material usage and the quality of the bound spine.
At Aayra Production, ACC is therefore not simply a machine feature. It has a direct connection to how the company manages its binding process.
Easier Operator Training and Machine Operation
Ease of operation is another aspect of the BW@2500 – a perfect binder for book printing, that Sameer highlights.
The machine’s touchscreen panel allows operators to understand what error is occurring and what production the machine is giving. Sameer says that operators can be trained easily compared with the older imported machines.
Operator availability had been a challenge with the previous equipment. According to Sameer, finding operators for those older imported machines was difficult.
The ability to train operators more easily has therefore become one of the practical advantages of the new binding setup.
Approximately 18,000 Books in a 12-Hour Shift
Production output is another area where Sameer provides a specific figure.
According to his testimonial, Aayra Production is achieving approximately 18,000 books in a 12-hour shift on the Bindwel BW@2500.
Importantly, Sameer says this figure includes the changeover time for different book titles.
This makes the figure particularly relevant to Aayra’s actual book-production workflow, where production can involve multiple titles rather than one continuous job.
The reported output is one of the clearest indicators of how the BW@2500 is being used on Aayra Production’s floor.
Reduced Wastage of Covers and Books
Sameer also identifies wastage as an area of improvement.
He says that the wastage of covers and books has been reduced compared with the previous setup, which he attributes to the new technology incorporated into the machine.
This is relevant to the broader economics of book production. Along with production output, the amount of material lost during the binding process can affect the overall cost of completing a job.
For Aayra Production, reduced wastage is therefore another part of the machine’s reported production impact.
Nearly 1 Lakh Books for an Export Job to Poland
Aayra Production has also used the BW@2500 for large production requirements.
One example mentioned by Sameer is an export job for Poland involving almost 1 lakh books.
According to Sameer, the quality of the completed books was good and QC rejection was “next to zero.” He says the company was very happy with the result.
These are customer-reported results from a specific production job. They provide an example of the type of large-volume book work Aayra Production has completed using the BW@2500.
For printers evaluating a perfect binder for book printing, real production experience can provide useful context beyond machine specifications. The relevant question is how the equipment performs when it becomes part of an actual book-production schedule.
Service Support as Part of the Machine Experience
Service and spare-part support were important considerations for Aayra Production because the company’s previous machines had become difficult to maintain.
Sameer says that after moving to Bindwel, the spare-part issue has not been a problem.
He also describes the service as excellent and says that some problems can be solved even through phone support.
For a production business, service is closely connected to machine availability. A machine’s value on the production floor depends not only on how it performs when running, but also on how quickly technical issues can be addressed when they occur.
Aayra’s experience with Bindwel’s perfect binder for book printing has therefore included both the machine itself and the support behind it.
Why Automation Is Becoming Important for Book Production
Sameer sees automation as an increasingly important part of book production.
He points to rising labour rates, increasing operating costs and higher costs per square foot. For Aayra Production, these pressures make it important to optimise production space and infrastructure while achieving higher output.
He also observes that processes across binding are moving towards greater automation.
Aayra Production is planning an assembly line as part of this direction.
The BW@2500 is therefore part of a larger production approach for the company, where automation and higher output can help address changing operating requirements.
A Binding Setup Built Around Production Requirements
For Aayra Production, the decision to install the Bindwel BW@2500, a perfect binder for book printing was shaped by the practical realities of running a book printing and binding operation.
The company was dealing with ageing imported machinery, limited spare-part availability, breakdowns and production that Sameer felt was not meeting expectations.
Since installing the BW@2500 in 2024, Sameer reports improvements in production quality and speed, reduced breakdown time, easier operator training, lower wastage and good production output.
He also points to the machine’s ACC [Adhesive Coating Control] technology, touchscreen operation and service support as important parts of the experience.
For Aayra Production, the Bindwel BW@2500 – perfect binder for book printing, has become its first Bindwel binding machine and an important part of its move towards higher production and greater automation.
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