Binding

Gluing Poly-Coated Substrates: Dyne Level

September 16, 2024

By Capital Adhesives

The process used to glue folding cartons or other products that are poly-coated and/or cartons that require a window film can create a series of challenges if pre-planning is not involved. In both instances, whether it be a poly-coated board stock or a window film to board, the surface is considered a poly surface and is not easily glued. The surface can, in fact, appear to be glued, only to have bond failure sometime after the process is complete. Below are key questions to consider when developing a strategy for improvement.

What does “dyne” mean?

Dyne is simply a mathematical term used to measure surface tension. All surfaces have a “surface tension,” but for a poly-coated surface to respond well to gluing it is important that the surface tension or dyne level of a poly board or film be equal to or greater than 38 at the time of gluing – noting that the higher the dyne number, the better the treatment. For incoming film or material that has poly coating, the minimum dyne should be 44 as it will lose treatment during the normal use and processing of the material.

What is a good process to manage dyne?

Five components should be managed to monitor dyne treatments of a poly material.

Purchase properly treated material with a specification as to the dyne level. As a reminder, the incoming treatment of a poly surface board or film should be 44 or greater.
Check dyne level and record results at time of receipt of the material. Sometimes a shipment will not meet the specification requested, but without the quality check upon receipt there is no way to be certain. Also, capturing the data will help identify reliable sources and provide the ability to track the degradation of the treatment.
Check dyne level throughout storage of material to avoid printing, cutting and gluing of low dyne materials – or at the least, to help prepare the manufacturing process for dealing with materials that have less than desired treatment levels.
Check dyne level at time of gluing as material will lose surface treatment within the process and storage. As previously mentioned, the dyne level at point of gluing is to be greater than or equal to 38 for more consistent results. As a note, there are special solutions and markers available for testing dyne levels. Dyne solutions are the best measuring tool and give more accurate results.
Work closely with an adhesive professional to identify test methods for measuring dyne levels properly and to identify the best adhesive product for bonding the poly surface material being used.

Does the dyne level of a poly surface stay the same?

Absolutely not. As stated previously, treatment levels dissipate from the moment they are treated. The average life span of a treated surface for gluing purposes is approximately 12 months. Aged poly-treated material is a high-risk glueable surface. The more aged a poly surface is, the more difficult it becomes to glue.

What can be done to help ensure the glueability of a poorly treated, low-dyne-level poly material?

In some applications, skiving the material provides a solution to a poorly treated poly surface, but skiving creates dust and oftentimes is inconsistent. A more reliable and cleaner process is to use inline plasma or corona treatment systems. These systems can be expensive, and proper use is essential to increase the consistency in gluing. Whatever the issue, having a knowledgeable resource that understands these challenging applications is essential. Aged poly-treated material is a high-risk glueable surface. The more aged a poly surface is, the more difficult it becomes to glue.

Does it matter what adhesive is used?

Emphatically yes. Too often, the wrong glue is proposed or used for gluing poly surface. The reality is that using the wrong glue will create more cost than any factor related to the price of the adhesive. Be cost effective more than simply price conscious. Choosing the right adhesive supplier will make money and retain better customer relationships. Selecting the wrong or cheaper glue may be more costly and create inconsistent gluing and wasted product.

As with any process, many factors contribute to success. The dyne level is not the only factor to consider when gluing a poly surface, but it is a critical component. Understanding and managing the “dyne factor” will promote a better first step in the process.

This article was submitted by Capital Adhesives, a leading supplier of high-performance adhesives and coatings. For more information, visit www.capitaladhesives.com.

Bindery Automation Circa 2024

March 18, 2024

By Brad Emerson, general manager, www.fixyourownbindery.com

What have printers and finishers/binders seen in bindery automation advancements in recent years? Beyond robotics increasing their labor-saving advantages with paper banding and palletizing, it pretty much has been digital bindery automation advancements. While most binderies realize the benefits of well-calibrated manual measuring devices to input format data on automatic makeready equipment, it’s time to fully embrace the ‘touchless’ bindery workflow, which works seamlessly, end-to-end, in a digital bindery. The word ‘touchless’ on digital lines seems to be smoking out the real-world ROI benefits of automatic makeready alone.

The digital bindery automation bar has been raised in single-book production. For many, digital perfect binding is all the same where (among sizeable digital binderies) two digital bindery production worlds exist: long-run digital (grouped size formats) and single-book production, where each book has a size format change. One of the latest digital perfect binders released seems ideal for both with amazing 2,000 c/hr production in single-book format mode and 4,000 c/hr when only the content changes. This hybrid two-digital-perfect-binding-worlds-in-one binder goes a step further with optional signature-feeder expansion on the same perfect binder to include conventional offset perfect binding for short runs, adding a third type of perfect binding in one machine.

Automation review

Training first and foremost

A cobot is a collaborative robot that is intended to work interactively with humans.

A manager’s training obligation isn’t completed by getting the PO number issued to bring in a training technician. Outside equipment trainers do not have the desire or bandwidth beyond the proper cycling machine to optimize the training to match the manager’s terminology, product mix, and existing systems and procedures. While it may seem ideal to train as many associates as possible, training three people works well. Fewer than three people may increase the cost per person and more than three people can lead to counterproductive sidebar conversations.

Before hands-on training starts is the perfect time to repair and tune the machine(s). Also, plan for a means to capture and transfer this valuable training expertise (usually video). If the ability to do in-house training does not already exist, seek outside options. Most original equipment manufacturers (OEMs) offer machine training on newer equipment. If new installation training at commissioning has been unsuccessful, find out what went wrong and incorporate lessons learned into the new training session. Operators might have to dig a little deeper to find an independent trainer(s) for legacy or obsolete equipment training. Whether an outside independent trainer is hired or an OEM technician, a highly skilled trainer or technician can teach maintenance technicians (in a separate session) beyond the operator’s routine minor maintenance duties.

Cobot automation
With the bindery labor shortage combined with rising costs over recent years, bindery cobots continue to arrive from major bindery equipment OEMs. This typically cage-free human/robot cohabitation is welcome in the bindery where relatively slow cobot speed does not restrict overall line output due to a particular plant’s product format mix.

Delta robots, which are popular in other industries (packaging), have yet to take hold in the bindery. Besides the Delta drawbacks of requiring interlocked safety enclosures, smaller x/y/z axis reach and lighter payloads, the major benefits cannot be denied: high-speed, lower investment cost and long-term cost of ownership savings of inexpensive maintenance-free components. Delta robots can cycle more than 10,000 cycles per hour, making them ideal candidates for bindery feeding and processing applications of ‘individual’ bound and unbound products. I hope any drupa bindery robotic releases this spring continue to accelerate this growing area of bindery automation.

Automatic and semi-automatic cartoning
Both automatic and semi-automatic cartoning have advantages and disadvantages. Semi-automatic cartoners have a distinct advantage over fully automatic cartoners as they allow the plant to produce extreme formats, plus they handle imperfect cartons. Trying to force a fully automatic cartoner near its format and size limitations in a general commercial bindery environment creates a manpower nightmare. When an extreme-size format job and/or off-spec carton shuts down an automatic cartoner for minutes, hours or days, a small army must appear to keep the line running, and then disappear when this carton job is finished – not a problem 30 years ago when a bindery had a few folks in the ‘handwork wings’ for such emergency tasks 24/7.

Palletizer automation
Whether a traditional palletizer or robotic palletizer, the ever-expanding palletizer installation base, combined with automated changeovers, is accelerating the transition from dedicated bindery lines to general commercial lines. Purchasing the right palletizer based on product format and speed requirements is only half the battle. It is important to visit/confirm with other satisfied palletizer users running similar product formats and production speeds before purchasing. Ask these questions:

How well can the palletizer process uncovered stacks with thin endsheets on work-in-progress hardcover book blocks?
Can the palletizer process variable height stacks when postal sorting?
Can the palletizer locally be supported to some extent? The pain is real with a palletizer down. Additional labor must appear and disappear as a palletizer goes up and down to maintain production schedules.

Gatherer feeding automation

A delta robot has three arms connected to universal joints at the base.

Processing difficult, thin paper stocks on new hard/softcover book binding lines has been realized with new thin paper adapters that now are on the market. The adapter gently allows the transfer of offset web press signatures for two-up production into the gatherer raceway, raising the industry bar in overall book quality and net production performance.

Printed digital roll automation
This is the most interesting and limitless area of evolving bindery automation. Whether a digital bindery is expanding its touchless capabilities or raising the roll width/‘feet-per-minute’ bar, the evolution from Gutenberg’s moveable type is most apparent.

We all have seen roll-to-stitched books or roll-to-perfect bound books, and more. From an unwinder into a sheeter into a folder or cut stacks, the possibilities seem endless except for electrical obsolescence. The only chance a digital bindery has against obsolescence is avoiding the complete ‘networked solution’ (if possible) when purchasing. Not only can a single component (unwinder or sheeter or folder or anything) of the overall line be powered off, but the network also remains satisfied if that component is permanently removed. Solid state and physical relay interfacing for upstream/downstream, stops/ready should not cause issues. And if an additional encoder is required to monitor upstream or downstream line speed to avoid the network, no problem.

Avoiding the network can create some touchless book data input challenges throughout the line depending on the OEMs, final line configuration and data handling. Upstream barcode scanners are great options, where possible. Preprinted laminated barcodes of a particular format to quickly wave in front of a scanner (or manually input data as a last resort) should be considered.

The elephant in the room

It was not by mistake that my first point in this article under the automation review subhead is ‘training first and foremost’ and not the latest in bindery automation equipment. The aftermath remains in our post-pandemic marketplace across many plants and industries – finding qualified personnel is difficult.

I know of no better path to the finish line than running smart and strong. Create the ‘perfect shift’ net production bar to be reached that is not just something easily achieved but celebrated with the bindery team. As a bindery manager, I always was fine-tuning my plans with my bindery personnel, whether taking longer or more frequent breaks to keep lines running or changing something responsively. Maximize the company’s entire investment: planning/implementing/training/running. Automation is necessary and will continue to be an important part of the bindery operation growth; however, people will remain the difference between success and failure.

Brad Emerson is the general manager of www.fixyourownbindery.com, a company specializing in consultation, consolidations, relocations, equipment sales and training. Email Emerson at [email protected].

In a Design Bind? Try These Unique Binding Options

June 5, 2023

By Erin La Row, editor, PostPress

Since the beginning of books, there has been a need for binding. When Hindi scribes in India began binding palm-leaf manuscripts together with twine during the second century BC, so began the craft of bookbinding. ¹ Over time, the need has remained, although the techniques have evolved.

For some, bookbinding is where art meets function. And despite the growth of ebooks, there’s still value in printed pieces that are tactile and aesthetically pleasing. Today, there are many binding methods – some simple, others more elaborate. There are so many creative options available that Sabine Lenz and the team at PaperSpecs created the “Binding Cheat Sheet” to empower graphic designers to “unlock their creativity and create printed pieces that WOW their clients.” Selecting the right style can make all the difference in the look and feel of a printed piece.

Most designers and others in the graphic arts arena are familiar with techniques such as saddlestitching, perfect binding, and mechanical binding options such as plastic coil and Wire-O, but they may not be aware of other specialty binding methods available today. A specialty binding technique could be what elevates a project to the next level. The following is a look at some unique binding techniques.

Japanese binding

Japanese binding, also called stab binding or hand-sewn binding, dates back centuries and today provides luxurious appeal. Sheets are hole-punched or drilled (typically, four to six times) and hand-sewn along the spine in various patterns. Books can vary in size from four to 480 pages. This is a technique that can be visually stunning when bright or contrasting thread colors are used. It’s important to note that this technique produces a book with a spine that does not allow the book to lay flat. There is no gluing or folding involved, providing a beautiful hand-crafted result without special machinery to create the binding. It is great for individual books or for extremely short runs of just a few, as it doesn’t require an automated process to bind.

Layflat binding

Layflat binding is more of a characteristic than a specific form of binding. Layflat binding allows for a book to remain open and the copy to seamlessly flow across a double-page spread. With layflat binding, a cold glue is thinly applied to the spine. The cover then is attached to the endpapers on either side of the spine, creating a visible gap along the spine. The cover spine is not attached to the book block. This technique provides a strong binding and high-end appearance. Applications for layflat include photobooks, cookbooks and children’s books where having the book open up and lay flat is important.

Automated layflat binding machines have become more accessible and affordable in recent years, which has been a driver in the growth of this binding process.

Loop stitching

Loop stitching is a variation of saddlestitching. In fact, it’s done using the same kind of equipment but with special stitching heads to form the loops. This technique is ideal for books with eight to 64 pages. With loop stitching, a wire is stitched through the document. Extra protruding loops of wire stick out on the spine to allow for the book to be used in a ring binder. A design tip is to use colored wire that can make the project really stand out.

Screw binding

This binding technique, also called Chicago binding, can be used for books of any size, although since it is a manual process, it’s typically best suited for one-off pieces or small runs. Loose sheets are collated to form the book block. Two or three holes are drilled along the spine, barrel posts are inserted into the holes and slotted cap screws are screwed into the barrel post by hand. The binding screws come in various sizes and colors to add visual appeal. This binding technique commonly is used for an application with several pages and for short runs.

Side stitching

With side stitching, individual sheets are stacked and then stapled together down the side from front to back. Staples are parallel to the spine and visible from the front cover. This method works best with smaller books, such as those with four to 160 pages, and often can be done using wire-fed saddlestitching machines.

Singer-sewn binding

Recognized by its stitched spine, the Singer-sewn technique allows the book to lie flat once opened. This technique is ideal for binding four to 60 pages and is created by using industrial sewing machines made especially for binding books. It includes a basting stitch that resembles a line of en dashes on the outside with a simple interlocking loop on the inside. Singer-sewn binding often is selected for its aesthetic appeal, especially when using bright or contrasting thread colors. This technique is not for very large runs but can be considered for small- to medium-sized applications.

Square back binding

Square back binding is created with the help of a special module that is added to a saddlestitch booklet maker. It applies pressure to the spine to create a squared appearance – also enabling printing to be added to the spine. It provides a professional-looking binding at a lower cost. This process works best for books with 24 to 200 pages. It’s an automated process that is a perfect solution for all print runs that usually would be saddlestitched. It provides a professional, clean look at a lower cost than perfect binding for most applications.

Book sewing (Smyth-sewn) binding

Book sewing, commonly referred to as Smyth binding or Smyth-sewn binding, provides a durable and high-quality finish for books. This binding allows books to lie flat when opened – a benefit for textbooks, cookbooks, notebooks or any books that need to remain open. Book sewing has seen many changes. What was once a very slow and tedious process now is automated with computerized machines for high-volume binding production. With this process, the machine stitches together individual signatures using binder thread. For extra durability, the signatures then are sewn together. This creates a text block that is sewn into the cover.

Another advantage of book sewing in the age of digital printing and quick turnarounds is that the finished binding can be proofed and validated as soon as it comes out of the book sewing machine. With a perfect bind where glue is used, it may take several hours for the glue or adhesive to dry before a final validation can be made.

Swiss binding

This technique is ideal for books ranging from four to 200 pages and often is used in combination with Smyth binding. Swiss binding refers to the way the text block is mounted inside a case – the text block is fully glued to the inside back cover of the case, leaving the spine of the text block exposed. Try breaking the rules and using a paperback outer case instead of a hardcover.

Tape binding

This technique also is called Fastback binding because it’s usually done with a Fastback thermal tape binding machine. Tape binding uses glue-coated strips that melt to the spine and covers of a book. The book block is loaded into the top of the machine with a binding strip placed into the feeder. Pushing a button moves the binding strip under the spine and heats it, activating the glue and forming the binding strip around the spine. It’s a relatively quick process, although books are bound one at a time, so it is best for relatively shorter runs. This is ideal for books with 20 to 720 pages.

PostPress magazine would like to thank PaperSpecs for input into this article. To get a copy of PaperSpecs’ Binding Cheat Sheet, visit www.bindingcheatsheet.com.

References

The evolution of bookbinding. Treasures of the McDonald Collection – Special Collections & Archives Research Center. (n.d.). www.scarc.library.oregonstate.edu/omeka/exhibits/show/mcdonald/bookbinding/bookbinding

DataGraphic Creates Smyth-Sewn Book for Global Diversity Movement

December 12, 2022

By Erin La Row, editor, PostPress

Many great design pieces begin with an idea. This one begins with a movement: Rare with Google – an initiative to help, in Google’s words, “change the face of a notoriously homogenous creative industry.” The team at DataGraphic, a US specialty printing company in Commack, New York, was tasked with creating what resulted in a stunning and unique book for the program.

To complete the assignment, the team had to dive into the mission. Rare with Google is a global diversity, equity and inclusion (DEI) program. According to the Rare website, “Rare with Google provides equitable opportunities for underrepresented creatives to thrive at every stage of their career.” Since its founding in 2017, Australian experiential design studio Semi Permanent has designed and produced Rare’s evolving program, which includes talks, workshops, mentorship opportunities and research projects. MAUD, an Australian design firm and a founding partner of Rare with Google, was the design company behind the program’s intelligent, punk-inspired graphic identity.

“Of the plethora of physical and digital assets created to support the program, DataGraphic was asked to produce this striking, exposed Smyth-sewn book,” said Glenn Schuster, president of DataGraphic.

While there’s nothing unusual about a Smyth-sewn book, what makes this one stand out is the exposed binding. Schuster said it’s a design trend: The book’s edges are not wrapped with a hard or soft cover, but intentionally left uncovered so the stitching and glue are bare to the touch.

“The Smyth-sewn binding was chosen by the creative director of the project since it lends itself nicely to the punk/D.I.Y. brand aesthetic that was used throughout the program’s creative assets,” Schuster said. “What makes this example of exposed Smyth-sewn binding unique is the layering effect created by the screen-printed clear PET dust jacket, which contains and protects the binding while leaving it visible.”

The project used 130# ColorPlan Lockwood Green for the cover and 100# Mohawk Superfine White Eggshell for interior pages. Machines used in production of the book include a M+R Screen Press for screen printing white gloss UV ink; HP Indigo for the interior printing; and a Smyth Sewing Machine for the spine binding.

Overall, Nicole Cappiello, account management and development with DataGraphic, said production went smoothly. The biggest challenge was being thousands of miles and an ocean away from the client.

“Working with clients overseas was a bit of a challenge. We typically invite our clients to come into our facility for press approvals and encourage involvement in the process as much as possible. We overcame this distance dilemma through our consistent communication,” she said. “In addition to this project having an ambitious schedule, we were able to meet the quick turnaround needed.”

Other than the challenge of distance, Cappiello said the project easily fell into place. “The technology and techniques used – it was nothing that wasn’t already in our wheelhouse,” she said.

The final result is a book that serves the spirit of the Rare with Google program, and one the design team is proud to showcase. “Our clients were very pleased with the outcome,” Schuster said.

Preparing for Today’s Bookbinding Applications

September 16, 2022

By Dianna Brodine, managing editor, PostPress

At the height of the pandemic, a significant increase in durable goods orders kept manufacturers producing at near record levels. Consumers who found themselves at home hit “add to cart” as they made purchase decisions on items to make their living spaces and daily lives more comfortable, including furniture, home appliances and entertainment options. One surprise winner in this shopping spree? Books. Even more surprising, the
spree continues.

According to a report from market research company NPD Bookscan, unit sales of print books increased 8.2% from 2019 to 2020, with 693.7 million print units sold. In 2021, 825.7 million units were sold – an increase of 8.9% in 2021 over 2020. Some of the early sales numbers were driven by panicked parents looking for resources that would replace educational opportunities lost when schools closed. However, with school back in session, young adult fiction books were the biggest driver of the 2021 increase, with unit sales jumping 30.7% according to NPD. Adult fiction sales rose 25.5%.1

Photobooks are another print industry staple that benefitted from consumers with time on their hands. Many took advantage of the opportunity to scan family photos or finally do something with the images on their cell phone cameras. Digital photobook production sites such as Shutterfly and Snapfish added new book sizes, paper stocks and design options to keep up with demand.

Two industry experts – Rick Salinas, president of Duplo USA, and Al Scolari, president and CEO of APS Imaging Solutions, Inc. – spoke about the trends in bookbinding during Amplify Print in Minneapolis, Minnesota, a first-time event aimed at those involved in print embellishments. During a panel discussion, Salinas and Scolari answered questions about binding processes on the rise, tactile effects, paper challenges and more.

Layflat and perfect binding take off during the pandemic

APS Imaging Solutions is a leading provider of digital lay flat photo book manufacturing systems and accessories to professional photo labs, photographers and studios worldwide. Over the last few years, Scolari has witnessed a surge of interest in lay flat binding, driven by an automated process that makes photo book production more accessible. “We specialize in the panoramic, full-image spread,” he explained. “That type of image is ideal for lay flat binding, and the professional photography market has taken notice. Over this two-year time period when everybody was at home, we’ve seen more photo books being generated – and that came along with a 30% increase in photo books done with perfect binding.”

Duplo USA Corporation also witnessed the growth of perfect binding. The company is the leading provider of print finishing solutions for the graphic arts industry, with highly efficient, modular products that streamline postpress production for digital color and offset applications. “Over the two years of COVID-19, perfect binding was absolutely explosive,” Salinas said. “People were trapped at home and bored, so they started ordering printed books again on sites like Amazon. That created a challenge because these days, when you order a book from a retailer’s website, that book doesn’t exist on a shelf.”

On-demand printing and inexpensive file storage changed the traditional book production and warehousing process. Now, when an order is placed, a file is downloaded and sent to the print facility closest to the consumer’s location. The interior pages are printed, a cover is manufactured and, within a couple of days, the book is on its way for delivery.

“Automation has taken book production to the next level,” Salinas said. “Paperback books are manufactured with this easy, on-demand perfect binding process, and now online booksellers are applying the same automated process to hardcover and lay-flat books to reduce storage costs and avoid low margins when stored books are sold to wholesalers.”

The visual and tactile effects of books

“Embellishments create intrinsic value out of nothing,” said Salinas. “Studies have shown that the more a product can touch the senses – see, touch, smell – the more it entices buyers. So, we see book covers that are foil stamped, embossed, debossed or finished with a soft-touch coating.”

Those print embellishments add visual and tactile elements to the cover of a book, drawing attention on a retail shelf and then enticing the consumer to pick a book up and hold it. This “haptic marketing” focuses on the tactile sensations that create a pleasing experience.

“Through studies, we know that if we can get a consumer to hold onto something, the brain begins to create ownership,” Salinas said. “So, the longer retailers can get purchasers to hold a book in their hands, the more chance there is that consumers will get hooked and take the book home. And, the more unique, the better! People don’t want a traditional book size anymore, so letter landscape formatting has become very popular. Duplo has just released our I Saddle 5.0, and every page in the book be a different size. Those unusual features increase the likelihood of purchase.”

Binding techniques play a critical part in that visual and tactile appeal. Lay flat binding appeals to the high-end coffee table book market. Saddlestitching can be done with an exposed, colored thread that adds a visual ‘pop.’ And raw edge paper adds another point of interest.

Scolari added, “It is all about creating something different. In some of our lay flat binding projects, whether children’s books or other types of printed books, we’ve added multiple inserts to build a thicker page that is extremely stiff. We’ve also had requests for the ability to use different types of substrates in one book, so one page will have a matte finish, but when the page is turned, the next image has a luster or metallic look.”

“Smell is probably the one sense that hasn’t been attacked yet in the printing industry, but I think we are going to start seeing it,” Salinas predicted. “Raised spot UV is something we’ve been doing for a number of years, and I think we’ll eventually see scented polymers come out as another way to attract buyers.”

Paper challenges in book production

Recycled paper stocks are another trend embraced by consumers. But, those stocks can cause problems with equipment throughput or adhesive bonding.

“The problem with recycled paper is that it’s recycled,” Salinas laughed. “To create a good-looking sheet, pulp and clay have to be added. It’s also a cost-cutting measure for paper manufacturers because the actual paper content in paper has gone down significantly. Clay is an inexpensive way to build up a piece of paper, but it can flake off during binding. Then the equipment or adhesive are blamed for failures, but oftentimes the substrate is the issue.”

Synthetic paper, often manufactured from plastic films, has gained in popularity due to its durability. “Synthetic paper looks beautiful when laid perfectly flat, but it doesn’t like to fold,” Salinas explained. “It’s hard to cut, and it’s very hard on the blades. We tell people that Duplo equipment can cut two million books on a single blade, but synthetics often reduce that significantly.”

Scolari said thicker, less flexible substrates also have an impact in the photobook production process. “We score everything with lay flat binding. So yes, we can use many different substrates and prints, but it’s very, very challenging to score a substrate that is stiff. The synthetic papers – and even some of the recycled substrates – can show discoloration after scoring. Sometimes, it’s better to look at a coil binding or perfect binding process.”

Focusing on the elimination of waste

A key component of today’s sustainability conversation is the reduction of waste. Automation is critical in the on-demand world of book production, where a print run may consist of just one book.

“The word ‘makeready’ is a thing of the past,” said Salinas. “When a run length is 13 sheets, you can’t have a 3% or 5% makeready margin. Automation is the only way to achieve zero makeready, and that has to be the ultimate goal for an operation that claims sustainability because every sheet that goes into the trashcan – that isn’t sellable – is created waste. Job flow software that ‘talks’ to the book production equipment as a print job moves through the system facilitates the elimination of waste.”

Scolari knows all about book-of-one production, since most photobooks are one-off orders. “It’s really about automation in regard to the layout, the tiling of the pages. It’s utilizing the material, especially when we’re using leather or other high-end materials. We use an overhead system that projects a tiling layout to eliminate waste and use each material in the most efficient way.”

There’s another often-overlooked source of waste in book production. “In the vast majority of printers in the US, the production staff has no idea of how much time they are wasting between steps,” Salinas explained. “If it takes 20 minutes to print, 20 minutes to bind and 20 minutes to ship, how much time is wasted in between those steps while walking the book block from the printer to the finishing device and then over to the packaging and mailing department?”

Understanding workflow is the first step in eliminating unnecessary steps during the production process. “Before print shops go out and buy a piece of equipment to improve their throughput and speed up production, they have to understand where they are wasting time,” Salinas said. “Then they will understand how to automate their processes to drive out the touch points, increase profits and reduce the chances for error.”

In a world where the printed book has made a comeback, but without the volumes of yesterday, automation is worth the investment.

References
“Print Books Had a Huge Sales Year in 2021,” Jim Milliot, Publisher’s Weekly, Jan 06, 2022, https://www.publishersweekly.com/pw/by-topic/industry-news/financial-reporting/article/88225-print-book-sales-rose-8-9-in-2021.html

Perfect Binding Automates: Handling Digitally and/or Offset-Printed Jobs

March 10, 2020

by Hallie Forcinio, contributing writer, PostPress

As printers face a greater mix of digital- and offset-printed jobs, shorter run lengths and a tight labor market, perfect binders have become more automated, flexible and connected. Traditional, large-volume printers are migrating to shorter, digital run lengths, while midsize digital shops doing print-on-demand, short-run batch and medium-run book production are growing and need higher output.

“Today’s ultimate perfect binding solutions are hybrid/crossover machines that have been configured to allow near-line applications for traditionally-fed offset-type products and also can be utilized to operate inline with digital front ends,” reports Mike Wing, solutions manager, Book Technology and Digital Solutions at Mueller Martini.

Delzer-Lithograph-Co — Randy Kornuth, bindery manager at Delzer Lithograph Co. (Waukesha, Wisconsin), operates the Standard Horizon BQ-480PUR perfect binder inline with the HT-80 three-knife trimmer for fast set-ups and changeovers for variable book production
runs ranging from book-of-one to thousands.

He adds, “Today’s ‘smart factories’ are driven by ultra-efficient touchless workflows that result in near-zero makeready by providing a seamless connection throughout the entire production line.” These workflows are enabled through (1) JDF job files that can be downloaded directly to the binder, or (2) binders utilizing barcode scanners at the infeed that identify and recognize each product – and its uniqueness – as it enters the line. Both methods enable the perfect binder to set up automatically and document each product’s parameters and integrity (e.g., page count, trim size, cover-to-content matching) during production. Smart systems also produce continuous data, pushing analytics back to management and operators so they can quickly identify bottlenecks and make changes whenever and wherever necessary.

With a tight labor market that makes it difficult to hire experienced or seasonal personnel, along with rising wages, the labor-intensive workflows of traditional bindery operations are no longer profitable. “It cannot be overstated that the addition of touchless workflows is essential to an industry experiencing both a reduction in labor and in skill sets,” says Wing.

Flexible equipment is needed to make it easy to adapt as business expands and/or moves into new markets. As the number of shorter runs grows, minimizing changeover time becomes critical. “Printers want to produce more titles per shift,” reports Rick Salinas, vice president of Marketing for Duplo USA Corp. Automation makes it possible to move from a 50,000-book shift with two or three titles to more than 50,000 with 10 to 15 titles.

Bourg-BB3202 — The Bourg Book Loader, or BBL accessory, converts its singleclamp BB3002 perfect binder into a 100+ pocket, self-feeding, autonomously operating machine.

“Automation has become the great equalizer,” agrees Jim Tressler, vice president of sales at C.P. Bourg. To automate the binding process, minimize labor requirements and eliminate waste, the Bourg Book Loader, or BBL accessory, converts its single-clamp binder into a 100+ pocket, self-feeding, autonomously operating perfect binder. The operator needs only six to eight minutes to load up to 120 book blocks into the empty clamps. Once loaded, the binding process begins, and the operator works on other tasks, returning occasionally to empty the delivery and load book blocks into empty pockets. The result is higher asset utilization and return on investment.

Vareo_1x2 — Mueller Martini’s Vareo three-clamp perfect binder boosts throughput by equipping each clamp with a drive that moves independently.

Another system with automated book block infeeds, Mueller Martini’s Vareo three-clamp perfect binder, on which each clamp has its own drive that moves independently, can operate continuously or as a “stop-and-go” binder for higher net throughput.

Caliper-equipped book clamps on Duplo’s DPB-500 binder accommodate run lengths of one. When the clamp closes, the caliper automatically reads thickness and scoring wheels, side glue wheels and cover positioning guide adjust. In variable mode, each book can be different. For longer runs, there’s a set mode. But, even in set mode, the caliper does a quick check of thickness to ensure the proper number of pages is present. The system also can incorporate barcode readers to check codes on covers and book blocks to ensure the two match.

“Additionally,” Tressler says, “we have made it possible to direct-connect the binder to multiple brands of printers and presses.” When operating inline, the Bourg Book Compiler, or BBC, accommodates cover- or batch-driven workflows. In either case, the customer preprints covers with a unique barcode identifier. When placed into the cover feeder, the code is read and the required content is immediately printed and bound, completely under process control with one operator. Tressler reports, “This workflow is ideal for runs of one or many and eliminates costly work-in-process and any manual touchpoints in manufacturing. By maximizing throughput and minimizing labor and waste, the increase in profits is enormous.”

Salinas notes there are other productivity-enhancing features, including bottom-feeding cover feeders and cooling towers. Bottom feeding permits cover replenishment without stopping the machine. Rotary cooling towers give books a chance to cure so they can be trimmed without damage and without any sitting time.

Today’s perfect binders also compensate for a wider array of substrates including coated and non-paper materials. Careful attention also must be paid to adhesive selection and spine preparation to ensure the book will perform under the environmental conditions it will experience. Ethylene vinyl acetate (EVA) adhesives remain common, but the use of polyurethane (PUR) is rising because it seals well on coated stocks, synthetics and polyester. “PUR dries not by cooling but exposure to air,” explains Salinas. “Once it cures, it isn’t going to come apart,” he explains.

“PUR does a great job on newer stocks with both pre- and post-print coatings,” adds Bob Flinn, director of business development at Standard Finishing Systems. With the growth in digital printing and its reliance on coated stocks, he says, “PUR systems are now more affordable, user-friendly and versatile.”

For Mueller Martini, advanced, thickness-variable PUR-nozzle systems apply adhesive more precisely, reduce daily cleaning/maintenance requirements and produce minimal waste in comparison to traditional glue pot systems. Integrated “adhesive monitoring systems automatically check for proper glue application and ensure each book is the highest quality,” says Wing.

The newest perfect binders also offer enhanced safety features and energy efficiency, plus a smaller footprint. As a result, newer machines typically deliver throughput and cost advantages over legacy equipment.

The fastest units for perfect binding operate at 18,000 books per hour. However, Wing says, today’s short-run, hybrid or digital work mixes are better served by slower speeds.

Tressler pegs this sweet spot for single-clamp machines at about 600+ cycles, or 350 books, per hour.

If faster speeds are needed, Salinas suggests a single-clamp machine capable of handling up to 1,000 books per hour, or a multi-clamp system that delivers 4,000 to 6,000 books per hour.

Next steps

The demand for books is growing. “…we are printing many more books today than ever in our history,” reports Tressler. He expects the trend toward much smaller quantities per order to continue. “The advent and impact of versioned, variable print and personalization is fueling this trend in all markets including pleasure read, vanity press, expressions and greetings, and others,” he adds.

Automation will continue to expand. The skilled operators needed to run legacy equipment are retiring, and it’s difficult to hire and retain new workers. “The new equipment makes it easy to bring new operators up to speed quickly,” says Flinn.

“Operators won’t be programming machines anymore,” agrees Salinas Major print producers are moving toward workflow-driven production where post-RIP data is sent directly to finishing devices. “Machine-to-machine communication will not only improve productivity but, more importantly, eliminate mistakes,” he explains.

Meanwhile, quality is more important than ever. Flinn explains: “In the old days, runs were high-volume and boxed up. A customer only saw a few books in a run. Today, with short runs, customers look at every book.” With any deviation noticed, book-to-book consistency is a must – along with a strong binding, square spine, accurate trimming and a mark-free cover.

With the higher levels of automation and flexibility being engineered into new perfect binders, it makes sense to replace legacy equipment. Today’s perfect binders can efficiently process variable products, one after the other and be run by fewer and less experienced operators. This makes it practical, even profitable, to run batches of one with completely different covers (hard or soft), trim sizes, paper stocks and customized content.

Finding the Perfect Recipe for Thick-Book Binding

December 17, 2019

By Katy Ibsen, managing editor
PostPress

There is no shortage of thick books in this world that required a special binding; text books, novels, educational tools, training manuals, dictionaries and so forth. We’ve all had the opportunity to connect with a thick book.

When a client brings a thick book to your bindery, it’s important to understand what they are trying to achieve in order to determine the best or most efficient type of binding. Questions to ask include: How many pages? Is there a desire for a spine, and will the number of pages accommodate having a spine? What type of front and back covers will be used? Will there be inserts or tabs in the book? What type of substrate will be used for the body of book (type of material, weight and print coverage % of the pages)?

To help understand this, we pay particular attention to these questions in the category of cookbooks.

Cookbooks are taking on lives of their own, now going beyond just an anthology of recipes. Furthermore, cookbooks are used for fundraisers and other special projects for social organizations like Junior League, or special interest publications produced by city/regional magazine brands. The design, photography, editorial content, paper and binding all play an important role in the book’s brand.

“Binding is such an important part of the printed piece and should be considered early on,” said Sabine Lenz, founder of PaperSpecs. “Not every binding technique is suitable for every purpose.” This growing trend creates new job opportunities for a bindery. Here, PostPress explores the options of binding thick books.

Coil binding

Coil or punch binding can be a popular option among smaller publishers or clients that have a project needing efficient binding that is not subject to style or branding. Examples include training materials, finance and legal documents, directories or regional cookbooks.

John Lugviel, vice president sales and marketing at Rhin-O-Tuff, shares more about punch and coil binding.

“Our solutions focus on lay flat binding because of its durability, lay-flat qualities and ability to be taken apart for document revisions,” he said.

Lugviel points to a study on binding by Interquest research, which revealed that coil binding is used for lay-flat documents more than half of the time.

Of the binderies/facilities surveyed in the Interquest study, lay flat proved to be the popular binding option.

The data states:

Training and education documents, marketing and sales materials, and finance/legal documents were the most common types of documents ordered with lay flat bindings, accounting for nearly 75% of those surveyed.
Top vertical markets ordering lay flat bindings included: Education (Higher Education and B2B), Finance & Legal, and Government & Nonprofit. At Rhino-Tuff, Human Resources, Sales & Marketing and Finance are the most common clientele.
86% of those surveyed reported that lay flat binding was applied to letter size, 8.5×11″ documents.
The survey revealed that, on average, 58% of the cover material is uncoated card stock, 18% is coated card stock, 17% of the material is clear acetate, 6% is vinyl and only about 1% is laminated.

Depending on a book’s content, design and layout, the punching will require some consideration. Lugviel says, “When choosing the best punch technology solution for your large book jobs, it comes down to volume and book structure, i.e. tabs, cover types and inserts. If you are binding many books with over 200 sheets (400 pages) per book, an automated punch may be the best solution. There are several high-speed punches in the market but only one that we are aware of that will insert tabs and difficult cover types, such as acetates, poly’s, UV-coated and laminated materials.”

For large jobs, Lugviel recommends an automated coil inserter with a plastic coil, with a 4:1 oval die. “There are several of these automated electric coil inserters available in the market. The costs for this type of equipment ranges from $15,000 to $30,000 until you get into the high-speed production category, which can go as high as $150,000,” he said. For wire-o (double loop wire) closing, Lugviel points out that there are a wide range of solutions from an automated standpoint, and they range from $30,000 to $150,000.

For small jobs, Lugviel suggests tabletop punch and binding solutions. “We would recommend a punch with interchangeable die capability,” he said. “This would allow users to use the same punch for plastic coil, wire-o and comb punch patterns.”

For plastic spiral binding elements for larger books, Lugviel recommends a 4:1 oval die pattern and a tabletop electric coil inserter. This pattern gives users a larger hole to insert the coil. If wire-o is required, a 3:1 (three holes per inch) round or square punch pattern is recommended for larger books.

Larger than 120 sheets, a 2:1 (two holes per inch) round or square die pattern would need to be used due to margins needed to bind the book without tearing the sheets. 2:1 wire standard sizes go up to 1 ½” and 300 sheets (600 pages) of 20lb paper. There are larger sizes, but they generally are custom made.

Thread sewn

Another popular option for lay flat and aesthetics is thread sewn binding. Also referred to as section sewn binding, pages are sewn together before covers are added, creating a visual effect that is also durable – ideal for cookbooks.

PaperSpecs, the online resource center for creatives working with paper, pointed to DISH cookbook, a special edition featuring recipes from famous chefs across Australia, as a beautiful example of Smyth sewn binding with bright blue thread that matches the book’s cover.

The Bindery, based in Australia, provided the thread sewn binding for DISH, which PaperSpecs credits for enhancing DISH’s “homemade feel, suggesting that this is indeed a piece to be treasured.”

Books that will experience some wear and tear are good candidates for thread sewn binding because there is an assurance that there is never a glue failure. The Bindery provides additional tips on best practice for thread sewn binding.

16- or 32-page sections are required for sewing. (If printing as four- or eight-page sections, then the job should be planned so as to insert one into another to make 16-page sections.)
Any odd 4pp or 8pp sections must be imposed to insert or wrap around a 16- or 32-page section.
All sections must have a minimum of a 7mm and a maximum of 12mm lap edge.
The lap edge can be either on the back half or front half of the section but must be on a common edge throughout all sections of the book.
All inserts and wraps must be the same size as sections and have the same lap edge as the sections.
All folded sections must be the same size from head to tail, and a spine measurement is required.

According to Lenz, books that show off the smyth sewing are on trend. She states that swiss binding is also popular, where the text block is glued to the inside back cover as opposed to the spine itself.

“Binding is a very important part of the overall design, the look and feel of a book, and thus should reflect the branding,” she said.

It’s also important to note that not all threads are created equal; thicker books have always been smyth sewn, to provide a lay flat quality and overall longevity to the book.

Perfect binding

Perfect bound cookbooks often are not as lengthy as their hardcover counterparts and will not lay flat; making it a less desirable option among publishers. The option is economical, however, and depending on the content of the book or trim size, may still have a purpose. It certainly is less costly, especially for large quantities.

Perfect binding a thick book with a soft cover will call for adhesive, and binderies have options: polyurethane reactive (PUR) or ethylene-vinyl acetate (EVA).

As previously covered in PostPress (see PUR or EVA – What is the Best Adhesive Option, Nov/Dec 2018), each has different qualities that might make it the correct option for different types of books.

PUR adhesive has many advantages. It can bind varnished, UV-coated, carton, mylar and other difficult stocks, where EVA adhesive may struggle with certain coatings or substrates. PUR also is compatible with digital printing because the kind of adhesive isn’t affected by ink migration.

Perfect binding can accommodate up to 400 pages and can be bound faster than thread sewn. PUR also provides a substantial adhesive, especially on coated papers and difficult paper stock, which makes it a better choice for larger books. The challenge of getting perfect bound books to lay flat is a challenge and must be looked at carefully.

Whatever the recipe, there are plenty of options for the perfect thick book binding.

Go Big and Go Gold – PBS Wins with Unique Binding

June 12, 2019

by Brittany Willes, contributing editor
PostPress

“Georgetown is a big idea, with a big future,” declared real estate development company Anthem Properties Group, Vancouver, British Columbia. Located in the heart of Surrey City Center, Georgetown is one of Anthem’s latest residential developments. In order to appropriately convey just how big Georgetown’s future is, Anthem turned to Thought Shop and Hemlock Printers to create a stunning promotional book for its clients.

Pacific Bindery, also located in Vancouver, British Columbia, was chosen to produce the bindery aspects of this project and was more than capable of rising to the challenge. The result was a softcover book that is just as big on visual appeal as Georgetown itself. The 10-acre urban community, which includes residential towers, townhomes, office and retail space, is beautifully depicted in 44-pages of full-color photographs, maps and architectural renderings.

Three rings of metallic, copper-colored foil combine to form a single letter – a bold “G” that stands out against a simple, navy background. The Georgetown G decorates the otherwise modest cover of the coffee table-style book. By opting to use a landscape format for the book, designers were able to make full use of an increased display area. The wider page styles allowed floorplans for the different buildings and apartments to be shown in larger sizes. Visually, it created a more impressive design that allows potential customers to get a better idea of all that Georgetown has to offer.

On a more practical note, the landscape-style also “allowed the pages to lay flat much easier than portrait pages that have a much narrower width and a much longer binding edge,” remarked Jean Stewart, account manager for Pacific Bindery. “It lends the book a great sense of presence when displayed on a table.”

The book cover itself was produced on 14 pt. Mohawk Carnival Cover in Deep Blue. Two different foils were used – the Copper #143 foil forming the prominent G and Gloss White foil used to spell out Georgetown along the binding, as well as Anthem’s name, logo and website on the back cover. Both foils were supplied by Great Western Foil.

Once the foiling was complete on the front and back covers, a register emboss was performed on the copper foil. Overall, the entire cover required two passes for the foiling, with an additional pass for the final emboss.

With the foil and embossing completed, an independent pocket then was glued onto the back cover. Next, D-tape was applied to the unfinished covers. The 44-pages of text were cut, collated and gathered together with the front and back covers. Finally, the book was bound using the relatively simple style of side stitching.

However, stitching was not the end of the binding process. A section of the stitched pages was folded and creased on a platen, creating a slightly raised portion along the side of the front cover. This raised section was hand-folded and manually taped, resulting in a unique look for the finished project.

“The look is a rare one,” Stewart explained. “We call it ‘Matchbook binding.’ It is a simple stitching job, but the wrapped cover over the stitching creates an altogether uncommon finished look.”

While the book itself may appear simple at first glance, the binding definitely garners a second glance that reveals something unique and special – just like Georgetown. The book has proven popular for Anthem. After being released for only a couple of months, Anthem requested further reprints for its clients.

At the 26^thAnnual FSEA Gold Leaf Awards, Pacific Bindery claimed awards in five categories, two of them for Georgetown in the categories of Most Unique Binding and Best Use of Foil/Embossing – Soft and Hardback Book Covers.

Q&A: Solving Challenges with Perfect Binding

March 11, 2019

by Jeff Peterson, editor-in-chief
PostPress

Perfect binding is an economic, attractive way to present information in a bound format for both short and long runs. Once viewed as a binding method for thick books or publications, perfect binders today are designed for quick turnarounds and much shorter runs, especially for the ever-growing digital world. And, it now is feasible to perfect bind page counts as low as 32 – or even less.

With the increased flexibility of perfect binding, it does provide additional challenges for the bindery and operator. Working through these challenges early in the design and set-up of the job can save time and money before the job hits the binder.

Q. What challenges occur during the layout stage of a perfect binding job? How are these challenges overcome?

Communication is key in the layout stage. Making sure the customer understands what is required early in the process can help decrease the chance of any unwanted challenges on the perfect binder. These may seem obvious, but a few simple things should be communicated early in the process to help decrease potential problems. First, page counts must be divisible by two. Also, printing and binding with the grain parallel to the spine on the paper stock will help decrease the chances of waves or cracking at the spine and help open the book with less resistance.

Another common challenge with layout comes when there are readacross sections or cross-overs (where the image or text must align across two consecutive pages). This becomes more of a challenge when the read-across sections are on two separate signatures. It always is best to keep this type of design within the same signature if possible and try to avoid this in the design all together if the two pages are on separate signatures.

When cross-overs do occur in the layout, they must be adjusted at the spine to compensate for the fact that a perfect-bound book does not lay completely flat. This can result in elements inside the gutter becoming lost within the center of the publication. When working with cross-overs, it is recommended to move the text or image approximately 1/16″ from the spine grind allowance over the normal 1/8″ (for a total of 3/16″) to help decrease the chance that the text or image will be “lost” within the glues used in the perfect binding process.

Another important item to communicate early in the layout stage is the impact of the use of glue traps. Glue traps are necessary to keep the glue from escaping when it is applied to the spine and side hinges of the book. It is recommended that the cover signature include at least an 1/8″ overhang over the inside pages. When the cover is attached to the book block, the glue will “squish out” from the head and the foot. If the cover overhangs the other pages, the glue will be trapped within the area needed to stick the insides to the cover. Diagram 1 demonstrates a common layout with appropriate margins for a perfect binding application.

cover diagram — >> Diagram 1: This diagram is a basic 2up layout of an 8½ x 11″ cover on a 19″ x 25″ press sheet. Note: The spine has the ink and coating knocked out in order to allow better adhesion of the book block. In addition to having the spine knocked out, it also is recommended to maintain a margin of ¼” on either side of the spine to allow room for hinge scores.

Q. How does stock thickness and/or spine thickness affect perfect bound jobs?

The thickness of the stock for the cover and inside pages can affect the speed of the perfect binder. Thicker books require slower speeds and greater accuracy in setting up the trimmer. However, thicker stocks many times will run more smoothly through the machine. It is important to know what thickness and specific type of stock that is being used to prepare for the job. Whenever possible, avoid printed 2-page sheets (2pp) on the perfect binder as they are thinner than folded signatures and can force the operator to slow down the binder speed in order to have the sheets jog-up properly with the other forms. Thinner signatures should bind between larger forms, ie: a 4pp form should bind between 16pp forms, rather than inside front or inside back cover.

Q. When are glue issues most likely to occur? How can adhesion issues be avoided?

Glue adhesion issues can occur whenever non-absorbent coatings and/or inks are used in the adhesion area. This is relevant in both the spine and side glue areas. As discussed earlier and shown in Diagram 1, knocking out these areas from inks and coatings can help eliminate glue adhesion challenges. PUR adhesives may be necessary for difficult inks/coatings and difficult stocks (see PostPress “PUR or EVA – What is the Best Adhesive Option?” November/December 2018). However, PUR adhesives are more expensive than conventional EVA adhesives.

Q. What improvements in machinery and adhesive have occurred in the last few years that decrease challenges with perfect binding?

Automation in perfect binding equipment is driven by a decline in run lengths, quicker turnaround requirements and the decreasing need for training and sophistication when running the machine. As run lengths continue to be shorter, quicker set-up and makeready times are a must.

Today’s machines have a higher degree of automation than ever before, with many different options for nozzle systems for glues; inline trimming of books with flush gatefold covers; barcode recognition for signatures and covers to prevent misfeeds; and book-block feeders. New and improved software also has an impact. Touchscreen technology today guides operators though each step of the set-up process, reducing the time required for setup and the likelihood of waste due to errors.

As stated earlier, PUR glues are versatile across a wide range of substrates and are good “go-to” adhesives for difficult jobs to avoid binding strength issues. EVA glues also have improved – with high-strength versions available for even smaller perfect binders. This type of EVA glue was developed with digitally printed work in mind, providing better pulls and reacting well to the paper being used with digital print.

PostPress would like to thank Larry Worfolk and Richard Sussey of Pacific Bindery Services Ltd. (PBS) for their assistance with this article. Located in Vancouver, Canada, PBS is the largest binder on the northwest coast, offering an array of binding and finishing solutions. Visit www.pacificbindery.com for more information.

Tips for Binding Large Documents with Coil

July 13, 2018

by Joe Bondonna, Spiral James Burn

For years people have attempted to come up with a better solution to binding large-sized documents using plastic coil. Some common quick fixes include:

Jogging books into oval-shaped channels
Inserters with rollers that have “gap space” adjustments
4:1 oval punching dies (oval dies can help)
Inserters that use mandrel drive systems, allowing you to split the book in half
Inserters with larger, more powerful rollers

All these are valiant attempts to solve the problem of large-format plastic coil binding. But most of the time for a document that is 40 millimeters thick, inserting the coil by hand is the only way that really works.

Tip #1: Use 3:1 pitch plastic coil.

The most common punching pattern for coil binding is 4:1 pitch. When binding a standard letter size document, there are 44 holes punched on an 11″ binding edge. This translates to 44 loops of coil that needs to get inserted into the document. Unfortunately, all these holes create friction, which restricts the coil and causes it to jam. This problem only gets worse as the book gets thicker because there is that much more friction.

By punching that same document using a 3:1 pitch die, there are only 33 holes punched on an 11″ binding edge. Because there are fewer holes, friction is reduced. Additionally, because the coil is spaced wider apart, 3:1 pitch plastic coil can be manufactured with thicker filament. This makes the plastic coil more rigid and easier to insert.

Tip #2: Use an oval punching pattern (3:1 pitch, of course).

When working with 3:1 pitch plastic coil, it is recommended to use an oval punching die (6.5×5.5mm). The key to this is using an oval hole die, trying to utilize a 3:1 pitch Wire-O round die doesn’t work well with these large books. When a thick book is being bound, the book will curve to follow the curve of the coil. As this happens, the punch hole “opening” is reduced. The expanded height of the 6.5×5.5mm oval hole provides sufficient space to keep this “opening” as free and clear as possible, so that the coil can wind its way through the punch holes unobstructed.

Tip #3: Use the right tools.

An old Chinese expression from an ancient text called the Analects of Confucius states “One must have a good tool in order to do a good job.” This is so true! We know that using 3:1 pitch coil and punching dies makes large document coil binding easier than using 4:1 pitch. There also are some special tools that will make a big difference in the inserting process. Here are a couple that work for us:

Slantis Coil Binding Sleeves: These are designed to securely hold the document while providing for the curved binding spine that conforms to the radius curve of the plastic coil binding element. This makes coil insertion much easier, especially on larger-sized books.
EZ Flex 100 Coil Inserter: This plastic coil inserter has been designed for use with the Slantis Coil Binding Sleeves for fast coil insertion on all plastic coil binding sizes, especially large coil documents. Unique in how the book stands upright in the slantis sleeves, these sleeves maintain the curve of the spine and the angle of the holes to match the coil. It has adjustable roller positions for high performance and easier coil insertion.

James Cash Penney, founder of the famous North American chain of department stores (JCP, also known as JC Penney), once wrote: “The keystone of successful business is cooperation. Friction retards progress.” The same concept is true with successful coil binding. By having supplies and tools that cooperate and retard friction, plastic coil binding for large documents can be done quickly and easily.

Joe Bondonna, product manager at Spiral James Burn, Totowa, NJ, has over 25 years of experience in the post-print finishing industry. You can connect with him on LinkedIn. For more information, call 973.256.0666 or visit www.spiralbinding.com.