What Is a Collator?

Ever flipped through a crisp magazine and wondered how it was put together so neatly? The answer is a collator – an easy-to-overlook machine responsible for assembling individual sheets of paper into sets.

In the past, large quantities of paper documents needed to be collated by hand. This was a slow, painstaking process with a high risk of human error. The introduction of machine collators in the 1940s revolutionised this task, allowing organisations to handle their growing workload with greater speed, accuracy, and cost-effectiveness. Today’s collators are even faster and more precise, making them an essential part of countless print shops, copy centres, and offices.

Col-Tec have been world leaders in designing, building, and installing high-performance collating solutions for over 50 years. We’ve helped countless industries across the globe streamline their processes, and in this guide, we’ll break down everything you need to know about machine collators, from what they do to how they work behind the scenes.

What Does a Collator Do?

Before binding, folding, or stapling, documents need their sheets to be arranged in the correct sequence. Collators eliminate the manual work required for this process by automatically sorting sheets based on predefined parameters. The result is significantly increased efficiency for businesses that deal with large volumes of documents.

What Are Collators Used For?

Modern collators are far more versatile than their simple description suggests. They can handle a variety of materials, from delicate tissue paper to heavyweight cardstock. Some collators fold, staple, and even trim pages, streamlining the entire finishing process.

Here are two common applications:

• Paper: In offices, print shops, and anywhere that deals with a lot of paper, machine collators are used to save time and effort. They can automatically sort and assemble loose sheets into booklets, reports, or presentations at much faster speeds than manual collation.
• Packaging: In factories and warehouses, machine collators can be part of an automated packaging line. They might be used to group and arrange products into specific configurations before they are placed in boxes or on pallets.

What Components Go Inside a Collator?

There’s no one-size-fits-all configuration for a collator, but they usually share the same base components:

• Input Trays: These trays hold separate sets of sheets that will be combined into a final document. The number of trays determines the maximum number of sheets per collated set.
• Feeder Mechanism: Each tray has a feeder mechanism that controls the single sheet feeding process. This ensures only one sheet is fed at a time.
• Collating Station: This is the heart of the machine where sheets from different trays are merged together in the programmed order.
• Output Stacker: The collated sheets are deposited here to form a complete set.

How Do Collators Work?

Collators come in a lot of different variations, but they generally follow a similar workflow. Here’s a breakdown of how they operate:

1. Each tray is loaded with a specific set of sheets that will form the final document.
2. The feeder mechanism in each tray pushes a single sheet towards the collating station.
3. A mechanism within the collating station precisely merges the sheets from each tray in the designated order.
4. The merged sheets are delivered to the output stacker where they accumulate to form a complete set.

Modern collators are electronically controlled, allowing you to program a variety of collating configurations. Many also have built-in detectors for missing or damaged pages, saving you from costly reprints.

Col-Tec: The World Leaders in High-Performance Collators

For over five decades, Col-Tec have been pioneering the design of high-performance collating equipment. We engineer and manufacture a wide range of suction feed collators, booklet makers, and optional equipment to handle projects of all sizes and complexities, all over the world.

Our industry-leading engineers are dedicated to providing you with the perfect solution, whether you need a simple collator or a highly versatile system for unique applications. We even offer cost-effective rentals for short-term use.

Col-Tec collators are renowned for their robust construction, reliability, and ability to handle a wider range of stock materials and sheet sizes than competing models. But if you have a specific need beyond our standard offerings, don’t hesitate — we also specialise in custom collator design and can tailor a machine to your exact requirements.

Ready to streamline your production process and achieve exceptional results? Book a consultation online or call us on +44 01425 627755, and let’s discuss how Col-Tec can create the perfect collating solution for your business.