Our Machinery

Production Capacity

Our Production Capacity

We produce, pick & pack and distribute content in various formats. Examples of these are: Education Books, Children’s Books, Trade Books, Annual Reports and Magazines.

We design and print education books such as Grade R School Books, Primary School Books, Secondary School Books, Supplementary Books, Teacher’s Guides, Activity Books, Learner Profiles, Sticker Books, Colouring Books, Distance Learning Books, Higher Education Books, Catalogues, Management Manuals, Technology Manuals and Training Manuals, among others. We deal with every aspect of Annual Report production including conceptualization, design and layout, selection of text and cover paper stock, printing, binding and distribution.

We print a diverse range of magazines and catalogues and quantities vary from 500 to hundreds of thousands. Our all-inclusive / one stop service includes conceptualization, design and layout, selection of cover and text paper stock, printing, binding and distribution.

This one-stop approach has proven to be extremely successful and popular as we have many happy clients repeating their orders on a monthly basis.

Printing Floor

Our Machines

Minimum sheet size – 340 x 480mm.
Maximum sheet size – 1020 x 720mm.
Perfecting – Yes – 4 over 4
16 page A4 sections – Yes
32 page A5 sections – Yes.
Maximum speed output – 12 000 sheets per hour – 4 colours on both sides perfecting. Suitable for multicolour CMYK bookwork, magazines, posters, labels, brochures and other general printing.
Stock ranges – 0.03mm to 0.6mm.
Alcohol dampening – Yes
Semi Automatic plate loading – Yes
Automated ink supply – Yes
24 hour a day capacity with 3 shifts

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Minimum sheet size – 340 x 480mm.
Maximum sheet size – 1020 x 720mm.
Perfecting – Yes – 4 over 4
16 page A4 sections – Yes
32 page A5 sections – Yes.
Maximum speed output – 12 000 sheets per hour – 4 colours on both sides perfecting. Suitable for multicolour CMYK bookwork, magazines, posters, labels, brochures and other general printing.
Stock ranges – 0.03mm to 0.6mm.
Alcohol dampening – Yes
Semi Automatic plate loading – Yes
Automated ink supply – Yes

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Minimum sheet size – 340 x 480mm.
Maximum sheet size – 1020 x 720mm.
Perfecting – Yes – 4 over 4
16 page A4 sections – Yes
32 page A5 sections – Yes.
Maximum speed output – 12 000 sheets per hour – 4 colours on both sides perfecting. Suitable for multicolour CMYK bookwork, magazines, posters, labels, brochures and other general printing.
Stock ranges – 0.03mm to 0.6mm.
Alcohol dampening – Yes
Semi Automatic plate loading – Yes
Automated ink supply – Yes
24 hour a day capacity with 3 shifts

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Minimum sheet size – 340 x 480mm.
Maximum sheet size – 1020 x 720mm.
Perfecting – Yes – 1 over 4
16 page A4 sections – Yes
32 page A5 sections – Yes.
Maximum speed output – 13 000 sheets per hour – one colour over four in perfecting or 5 colours on one side. Suitable for multicolour CMYK bookwork, magazines, posters, labels, brochures and other general printing.
Stock ranges – 0.03mm to 0.6mm.
Alcohol dampening – Yes
Semi Automatic plate loading – Yes
Automated ink supply – Yes
24 hour a day capacity with 3 shifts

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Minimum sheet size – 340 x 480mm
Maximum sheet size – 1020 x 720mm
Perfecting – Yes
Maximum speed output – 10 000 sheets per hour – one colour on both sides or 2 colours on one side
Suitable for single colour bookwork, or spot colour general printing
Stock ranges – 0.03mm to 0.6mm
Alcohol dampening – Yes
Automated ink supply – Yes
24 hour a day capacity with 3 shifts

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Maximum reel width – 920mm
Cut off – 630mm. 4 over 4 print units
Reel to sheet – Yes.
Reel to folded sections – A3, A4, A5.
Maximum speed output – 60 000 revolutions per hour
Stock range – 48 gsm to 135 gsm
Automatic register control – Yes.
Alcohol dampening – Yes.
Suitable for long run multicolour CMYK bookwork, magazines, brochures, leaflets and forms.
16 hours a day capacity with 2 shifts

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Maximum reel width – 965mm
Cut off – 630mm. 5 over 5 print units
Reel to sheet – Yes.
Reel to folded sections – A3, A4, A5.
Maximum speed output – 65000 revolutions per hour
Stock range – 48 gsm to 135 gsm
Semi Automatic plate loading – Yes
Automatic webbing up device – Yes
Automatic register control – Yes
Alcohol dampening – Yes
Suitable for long run multicolour CMYK bookwork, magazines, brochures, leaflets and forms.
16 hours a day capacity with 2 shifts

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Reel Width – 520mm.
Cut off – 610mm.
Reel to reel printing.
Reel to sheet printing.
Inline camera quality control – Yes.
Inline die cutting, kiss cutting and creasing – Yes.
Inline perforating, file hole punching and sprocket punching – Yes.
Inline UV varnishing – Yes.
Inline variable data – Kodak Versamark / Domino – Yes.
Inline sheeting and stacking – Yes.
Perfecting – Yes – any configuration within the 9 units.
Maximum output – 305 meters per minute.
Stock range – 48 gsm to 250 gsm.
Suitable for multicolour CMYK and spot printing of labels, posters, brochures, leaflets, security printing, covers, stickers and a variety of other general printing.
Alcohol dampening – Yes.
UV inking – Yes.
Continuous feed and delivery – Yes.
16 hour a day capacity with 2 shifts

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This full colour digital engine is capable of outputting full variable data, full colour A 3 sheets.
Maximum sheet size – 320 x 460. Maximum speed 3300 A3 sheets per hour (full colour variable data).
Automated colour calibration and inline. spectrophotometry.
Resolution 600 x 600 DPI.
High performance Xerox Freeflow RIP.
The Xerox iGen 3 is perfectly suited to full colour, full variable data printing of short runs and barcoding and numbering are easily dealt with on this press.

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The Bourg Document Finisher is fitted to the back end of the i Gen 3 and can produce A4 and A5 saddle stitched books on demand and inline.
Lebone Litho uses 4 high volume Xerox Docucolour 252 machines in their short run digital facility.
These machines are each capable of running up to 200 000 sheets of A3 paper a month full colour on both sides. Sheet sizes can be A4 or A3.
Paper handling from 64 gsm to 220 gsm.
Print resolution 2400 x 2400 DPI.
Speed output for colour printing is 50 pages per minute. Our OCE Vario Print 6250 series Black & White full variable data, duplex digital printer is suitable for up to 8 000 000 black and white prints per month.
Size of paper range is A4 or A5. Speed output A4 – 250 prints per minute.
Speed output A3 – 130 prints per minute. Print resolution – 1200 DPI.
Paper handling from 60 gsm to 200 gsm.
The CMT 330 digital perfect binder is fitted to the backend of our OCE VarioPrint 6250 and is capable of delivering perfect bound books on demand and inline

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Our fully programmable Polars can cut various jobs ranging from a small 50 x 80 mm up to a full sized 870 x 1200 mm and can each store an impressive 100 cutting programs.
The built in safety features ensures that the operator can use the machines without fear of being injured on duty.
An example of these safety features is the light beam technology which will stop the blade travel instantly should the beam be broken during operation.

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Lebone Litho has 3 high speed MBO B30 – 16 buckle folding machines.
Multiple folding capabilities including: conventional 16 page and 32 page folds, zig zag 32 pp, roll fold, gate fold, concertina fold, 4 pp and 8 pp folds etc….
Continuous round pile feeder Maximum sheet size760 x 1300 mm Inline perforating and scoring facilities
Maximum speed output – 183 meters per minute

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We have a small Stahl KB 36 folding machine and typical use is for Pharmaceutical leaflets.
It has 6 pockets and an inline chopper folder.
Maximum paper size – 360 520 mm
Paper handling from 48 gsm upwards

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Our Aster book sewing machine is perfectly suited to the hard cover and thread sewn book market.
The machine is capable of 150 cycles per minute
Maximum signature size – 320 x 380 mm.
Minimum signature size – 80 x 150 mm

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Lebone Litho has 3 high speed MBO B30 – 16 buckle folding machines.
Multiple folding capabilities including: conventional 16 page and 32 page folds, zig zag 32 pp, roll fold, gate fold, concertina fold, 4 pp and 8 pp folds etc….
Continuous round pile feeder Maximum sheet size760 x 1300 mm Inline perforating and scoring facilities
Maximum speed output – 183 meters per minute

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6 signature loading stations
Cover feeder 3 knife trimer
Perfetto compensating stacker
14000 per hour speed output
Maximum size – Tabloid
Minimum size – A6
Oblique sheet monitor (no double sections)
Automated signature recognition (no misplaced signatures)

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We have a state of the art Corona CC 12 Perfect Binder capable of binding books up to A4 size at 12000 books per hour.
These can either be Hotmelt or PUR glued.
The machine is fed by a 15 station gatherer and the books are precision trimmed on the inline Zenith 3 knife trimmer before being counted and stacked automatically in preparation for a speedy delivery.

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Printing Machines