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Manufacturing Services


The success of the pre-press production environment at GlobalWare Solutions is based on employing discrete technologies that are networked to function as a single system. These technologies include:

  • PostScript-based printing environment

  • Flexible network architecture 

  • Internet as a data transfer medium

  • 60 gigabyte raid array on-line storage system and a 15 terabyte offline storage system for customer data libraries

  • Pre-flight testing of files using Adobe Acrobat and Infocus Double Check

  • Multiple computer-to-plate systems

  • Digital color proofing systems

Managing this system of interrelated technologies is a dedicated staff of professionals, that test, file, track and archive customer files two shifts a day GlobalWare's pre-press management system is specifically designed to manage the pre-press environment in a totally automated manner.

Printing (Offset and On-Demand)

Targeting our expertise to the needs of the computer/software industry and information- based companies, GlobalWare Solutions has developed a specialized niche in one and two color books with multi-color covers. The capacity of our heat set webs exceeds 34 million pages per day. Our Harris M-1000 heat set web produces interlocking 16s and 32-page layout with full 8 1/2 X 11 pages. Our Timson T32 web is specifically designed to manufacture 7 X 9 books with greater cost efficiencies. Our 8 sheet fed presses with up to 6-color capability print an additional 15 million pages per day. Our presses run 24 hours a day at speeds up to 30,000, 32-page signatures per hour to meet our customer's needs for one, two and four color printing on coated and uncoated stocks. Folding capabilities include broadsheet, tabloid, oblong, digest and catalog.

In order to meet our customers' growing needs for instantaneous and simultaneous release of new products, we have become one of the largest fully networked, on-demand documentation publishers in the U.S. Our on-demand print center capacity exceeds 1,600,000 pages per day. Each one of our multiple electronic presses with in-line binding can complete a 600-dpi book in a minute. Keeping up with technology we've added the latest in digital color printing to further meet our customer's needs for short run color documents along with the first installation in the United States of pinless digital web press. This new digital press is four times faster than a Xerox DocuTech system and can do variable data on the fly. GlobalWare's Raid Array storage system within the MediaBank management system provides instant access to a 15-giga-byte library of on-demand print files, which allows us to produce any document our customers need immediately.


Box Printing and Manufacturing

One of the most important components of any software package is the outer box or retail box. The box has the longest lead-time to manufacture and typically ranges from 3 to 6 weeks. In order for us to continue to reduce the lead-time for the manufacture of software products, GlobalWare Solutions realized that we needed to manufacture the boxes used in the majority of the products we build.

 In 1998 we installed in our printing plant a KOMORI, 5-color press with aqueous coating, capable of printing on heavy stocks up to 32 pt.  This press can produce retail boxes, O-wraps, CD-ROM sleeves and a wide variety of packaging items up to 26"x40" in size and at a rate of 7,000 pieces per hour. With this press GlobalWare Solutions now has all of the manufacturing assets in house to produce the majority of the components used in a typical software product, which insures our customers, the fastest delivery in the industry.

Finishing and Binding

GlobalWare Solutions has an extensive in-house 35,000 Sq. Ft. bindery operation with capabilities to produce 200,000 books per day with perfect and lay flat binding, saddle stitching, Wire-O binding, GBC and 5-hole drill and shrink wrap. A complete list of bindery capabilities is shown on our equipment list.

CD-ROM Manufacturing

 Both precision and speed are essential to CD-ROM manufacturing. GlobalWare's reputation for quality has been replicated on our high-speed, high-precision CD-ROM manufacturing lines. Our 60-ton CD-ROM injection molding presses produce the highest quality CD products available. 

Using the very latest in robotic technology, an optical-grade resin is injected onto a metal stamper that creates clear plastic discs impressed with microscopic pits on one side. This data surface is immediately metalized with a layer of clear aluminum atoms, adding the reflective surface enabling disc playback. A durable lacquer coating which protects the aluminum is then applied.

 Silk screening of CD labels incorporating up to five colors is completed on our manufacturing line. CD-ROMs along with printed booklets and inlay cards are automatically assembled into plastic jewel boxes for kitting, warehousing and distribution. ZBR has the capacity to produce 50,000 CD-ROM's per day and over 18,000,000 CD-ROM's per year.


Diskette, Tape and CD-R Duplication

 GlobalWare Solution's duplication technical staff works with our customers during the pre-mastering of all media to ensure that computer files, slides, graphic, audio and video information meet the appropriate logical formatting and indexing requirements for error-free media and CD-ROM conversion. We work with a variety of transfer media including rewritable optical discs, 9-track tapes, data cartridge tapes, WORM, floppy disks, microfilm and graphics.

 GlobalWare is a single-source solution for all your information integration, replication and distribution needs. We offer a full range of duplication services for 5.25" and 3.5" disks, 4mm, DAT, 9mm, TK-50, QIC and now extensive capabilities for CD-R duplication and labeling. We do virus scanning, data verification and cross-verification, quality testing, laser label imprinting, serializing, collating, sleeving and turnkey assembly of all soft-copy materials.

Product Assembly

 As a single-source turnkey vendor, GlobalWare Solutions manufactures all components for product kit assembly. Our multiple high-speed assembly lines and on-demand kit building systems can build up to 100,000 customized product kits per day for bulk distribution or individual order fulfillment. Computerized kitting, warehousing and inventory management services provide just-in-time distribution of books and media worldwide.

Fulfillment and Distribution

 Fulfillment has become a key to the success of GlobalWare Solutions in the past few years.  Our ability to provide on-demand fulfillment to our customers has enabled us to maintain and grow our revenue stream through this value added service.  With the explosive growth of the Internet, it is imperative that "customer direct access" to product information be made available.  We have invested heavily to ensure that our capacity exceeds our customer's demand for this service.

We maintain extensive warehousing capacity and a computerized materials management system to ensure just-in-time distribution of all books, media and product kits. For many of our full service/turnkey business partners, we manage worldwide product distribution, inventory and warehousing. Our business partners interact directly with GlobalWare through our Web Site  tools to access manufacturing management data and to monitor project status and shipment transactions.  Managed efficiency means managed costs.

Our capabilities to receive distribution orders include our Web page Distribution Ordering system, ANSII X12 EDI and Email for both customer and End User requests. We can receive orders for same day fulfillment up to 3:30 EST.

We have shipping arrangements with most of the major carriers.  These carriers meet all the requirements for both domestic and international deliveries.  We ensure all shipping information required is included and traceable via our Web Tool ProductTrac(tm).



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