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      PostPress

      PostPress

      Print Decorating, Binding and Finishing

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        Enews July 2023

        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.

        Layflat binding
        Photo courtesy of APS

        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

        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
        1. 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

        Industry Influencer: Adam Peek

        June 5, 2023

        Adam Peek is passionate about family. He’s also passionate about packaging. The
        husband and father of five children has found a way to combine his passions into a fascinating and rewarding career as a self-proclaimed evangelist for the packaging industry. Over the 15 years that Peek has been in the packaging industry, his resume reads more like an adventure book: packaging company executive, ordained Baptist minister, podcast host, sustainability consultant, trainer, global speaker, soon-to-be-published children’s book author… and part-time rapper.

        Peek graduated from Colorado State University with a bachelor’s degree in business administration. He then earned a Master of Business Administration with blockchain and supply chain concentrations from Quantic School of Business Technology. Peek is a licensed and ordained reverend through the Southern Baptist Convention.

        Peek recently partnered with PostPress magazine to talk about his career, sustainability in the packaging industry and emerging trends.

        How has your career developed in the packaging industry?

        I started with Peek Packaging (our family business) and it was a great job, but then I moved back to Colorado Springs to start a church with some friends. I thought I was done in packaging and eventually would be a full-time pastor. While the church was taking longer to get off the ground, I got a job at WS Packaging Group in sales, and that was really where I figured out packaging was awesome! From there, I had a short season at Fortis during the COVID-19 pandemic before accepting my dream job at Meyers Printing, a Minnesota-based packaging, label and retail display company, where I’m currently the senior vice president of sales.

        You describe yourself as an “evangelist for the packaging industry.” What is it about packaging that gets you fired up?

        Evangelist means bringer of good news, so I really try to focus on finding good news to share about the industry. There’s always going to be negativity because ultimately we are creating trash, but there’s so much value and goodness that can be found in what problems packaging actually solves that I choose to get excited about those areas, for sure!

        How has the packaging industry embraced global issues such as circular economy and sustainability?

        I think out of necessity the industry has been forced to adjust to the demand for larger-scale sustainability, along with innovating to create unique advantages in the marketplace. We haven’t yet done a great job of telling the stories about what it is we actually are doing, and I hope I’ve helped make a small dent in sharing through my podcast, weekly news show on LinkedIn and children’s book, Packaging Peeks and the Sticky Situation, coming out in August 2023.

        Embellishments, such as foils and specialty coatings, continue to be very popular with packaging (carton and label) applications. Why do you think this is the case? What advantages do you believe special embellishments bring to the table for the brand owners?

        Brands have very little time to capture attention on the shelf. Not only are they competing with the other brands, but with cell phone use at such a high rate, they also are having to compete with the screen. Even DTC (direct-to-consumer) brands need to create unboxing experiences and attention-grabbing packaging in homes. So, embellishments continue to be used by these brands as a means to grab attention.

        The advantage brand owners get is the ever-sought-after currency of attention and eyes on their product. Even though the cost of attention is much higher, the cost of lost sales and market share is catastrophic in many cases.

        Meyers recently went through a brand refresh to reflect its leadership in the sustainable packaging industry. Explain what it means to you to work at a company that shares your passion for sustainability.

        Along with the brand refresh, we also compiled a free 64-page e-book about sustainability in packaging. It has helped to define our “why” as a company and to work with people who have similar passions. I’m one of those people, so being tapped to be a co-author on the book really showed how much the company values me and how committed it is to the new company direction.

        You’ve talked to a lot of people through your “People of Packaging” podcast. What’s the best advice you’ve received from a guest?

        Honestly, it is really, really hard to nail down one thing as “best advice.” I will say one person who has stuck out is Darrell Jobe in what he’s built at Vericool. His
        story – from being a gang member to the CEO of one of the more sustainable packaging manufacturers in the world – is remarkable! Editor’s note: Listen to Peek’s People of Packaging Podcast at www.peopleofpackaging.com.

        What are the biggest challenges facing the packaging industry?

        There are many challenges for sure, but one of the biggest is that we are not attracting young, innovative and diverse talent to our industry, which will stagnate our ability to make the changes necessary as the industry moves forward.

        What are some of the emerging trends that you believe will influence the future of the packaging industry?

        Extended producer responsibility (EPR) is going to come in really strong across the planet, so the industry, along with brands, will have to learn to navigate both consumer demand and political regulations, which will vary from country to country and state to state. There also will be a significant challenge in how we feed 10 billion people while doing minimal to no damage to our climate. Packaging will play a significant role there as well, I think.

        What advice do you have for people entering the packaging industry?

        Surround yourself with people who will foster a growth mindset in you. The industry is wonderful and full of many incredible people, and we get to solve big, incredible problems together. Find the people and career path where you experience joy and you’ll realize what I did – that packaging is awesome!

        DVC Highlights Striking Foil Capabilities Using Cast and Cure™ and Cold Foil

        March 15, 2023

        edited by Erin La Row, editor, PostPress

        A company’s success is tied to its employees telling the brand story and effectively showcasing capabilities to potential clients – something the crew at D’Andrea Visual Communications (DVC), in Cypress, California, knows all too well. The company began in 2005 as a lithographic printer. It has since expanded in-house with grand format printing and custom fabrication. Today, the company is a visual communications producer for Fortune 500 brands as well as start-ups.

        Cold foil is a DVC hallmark – the company needed a visual way to demonstrate its capabilities to clients. Using previously designed graphics the company had on hand, designer Franz Dreikorn, prepress/pressroom manager at DVC, got to work designing a sample booklet.

        “We needed to show what we can do as far as foil and Cast and Cure™,” Dreikorn said. The result: an eye-catching booklet that pops with color and shine – showing potential clients the DVC team knows how to help their businesses get noticed and excite customers. Dreikorn said 100 lb. book-weight stock was used. “We wanted to show the difference between cover stock and book-weight stock,” he added.

        The Cast and Cure film was supplied by Breit Technologies and the cold foil was supplied by Univacco Foils Corporation. The machinery used in the production of the booklet included a KBA Rapida 106 press with an Eagle Systems cold foil unit. The six-page booklet took home Best Use of Film Casting (Cast and Cure) from the Foil and Specialty Effects Association’s 2022 Gold Leaf Awards.

        “I was pretty happy,” Dreikorn said about the award.

        The inside pages of the DVC booklet include an example of cold foil only, showcasing its ability to do both larger solids and reversed-out type. Another page demonstrates reversed-out 4-color litho with a Cast and Cure clear holographic background, and the middle of the booklet includes a beautiful two-page spread of a city skyline with a pass of silver cold foil that then was overprinted with 4-color litho – all inline on the KBA press and Eagle cold foil unit. The last two pages showcase a color chart of CMYK colors available for printing or overprinting with silver foil.

        The DVC booklet includes a reversed-out, 4-color image with a Cast and Cure™ clear holographic background.

        Cast and Cure is a decorative process that uses UV/EB varnishes and specialty films to create diffractive surfaces that produce unique finishes for the printing and packaging industries. It forms a consistent high-quality surface that can incorporate ultra-high gloss, matte and holographic finishes on a variety of substrates.

        “It gives you a better sheen,” Dreikorn said. “It’s brighter – more of a mirror effect.”

        Tim Cain, president of Breit Technologies, Overland Park, Kansas, said, “D’Andrea understands that the Cast and Cure process is more of an overall effect and not just a highlight. Many people use foil as an accent. Due to the reusability of the casting film, an overall Cast and Cure effect can be applied to the whole piece for the same cost as a traditional foil highlight.”

        Cain added, “One of the undiscussed benefits of the Cast and Cure process is the enhanced gloss level. The casting film works to calendar the coating to a consistent level, enhancing the gloss level and offering an additional boost with the holographic effect.”

        Breit Technologies is credited with introducing Cast and Cure in North America. PostPress previously sat down with Cain to talk about the Cast and Cure process. Cain said it is used in everything from liquor and beverage labels, printed collateral and direct mail to magazine and book covers, and even food and pharmaceutical cartons.

        “Brand owners find the clear holographic patterns are an excellent way to grab the consumer’s attention when they’re applied to a carton or label,” Cain said.

        The process has many benefits. Since the Cast and Cure film works as a type of mold for the cured UV coating (the film is not actually applied to the substrate), it can be used up to a dozen times – sometimes more – and volatile organic compounds (VOCs) are eliminated with the use of UV/EB varnishes. Less money is spent on shipping fees and warehousing compared to other decorating methods, and the casting films are recyclable.

        When asked about clients’ reactions to the booklets, Dreikorn said, “Everybody loves them!”

        7 Steps to Turn Employee Potential into Performance

        September 12, 2019

        by Brad Wolff, managing partner
        PeopleMax

        Imagine coming to work on Monday to discover that the company’s meticulous, rule-following accountant and creative, eccentric marketing person have switched positions. How’s this likely to work out? In truth, some variation of this misalignment is common in most organizations. An employee alignment process puts the right people in the right seats.

        Understanding the alignment problem

        Most business leaders say that 80% of the work is done by only 20% of the workforce. The 20% are the top performers – and they usually produce three to four times more than the others. The main reason can be attributed to correct job alignment, rather than attitude or drive.

        Here’s evidence: It’s common for top performers to be moved or promoted … and then they become poor performers. Likewise, many poor performers become top performers when moved to appropriate roles.

        Bottom line: Everyone can be a top performer or a poor
        performer, depending on how well the work aligns with their innate characteristics.

        Putting employees in the right seats

        How can an organization be deliberately created to align an employees’ work with their innate characteristics (abilities)?

        1. Shift the mindset away from focusing on skills, experience and education.

        It’s common for people who are “great on paper” to get hired and become poor performers. In that same vein, many top performers started off lacking in the “required” skills experience and education. When people’s work aligns with their innate characteristics, they can utilize their natural abilities and unleash their passion for their work. Also, the best training system and management team will not turn poorly aligned employees into top performers.

        2. Select the right assessment tool.

        Many organizations use personality assessments in the hope of gaining more objective information about people to set them up for success. However, the results can be disappointing due to the following inherent pitfalls:

        • The traits typically thought of as “personality” are mostly surface-level, observable behaviors – not what’s underneath. The drivers of behavior are more accurate, predictive and stable.
        • Assessment-takers may provide different answers based on which of the following they consider: how they actually see themselves, how they believe others see them and how they want to see themselves.
        • Assessment-takers use a specific context or situation to answer the questions. For example, answers to questions related to “extroversion” (sociability and talkativeness) may vary depending on context differences (small vs. large groups, familiar vs. unfamiliar people, level of interest in the topic of conversation, etc.).
        • If an assessment is used for a job application, the applicant may have an opinion on what traits the employer is looking for and skew the answers accordingly.

        What’s a better option? Select an assessment that delves beneath the personality into what is more core or innate with people. This eliminates the biases of personality assessments and provides more valid and reliable data.

        3. Establish trust with the employees.

        Inform the employees about the company’s commitment to align their work with their natural gifts. Don’t hide things or surprise people. People want to do work they’re good at and enjoy.

        4. Develop an understanding of the innate characteristics being measured.

        Before people’s innate characteristics can be aligned with their work, it’s essential to understand what these characteristics mean. In other words, how does each one impact the way people think and behave. This provides the basis to identify which characteristics are needed for different types of positions within each organization.

        5. Develop clarity on the job duty breakdown.

        It’s important to know what people will do on a day-to-day basis in each job. The hiring team (direct manager and others with a major stake in each position’s success) meets to gain clarity on the percentage of time spent performing each job responsibility. Duties that are very similar in nature (family of duties) should be grouped together. Estimate the percentage of time spent working on each job duty family.

        6. Determine which innate characteristics are critical.

        The hiring team determines which innate characteristic is critical for each job duty family. The team also should agree on the desired range for each characteristic. For example, on a 1 to 10 scale, the range for creative thinking should be between 7 and 9 for certain positions. An optimal range should be developed for each critical characteristic.

        7. Administer assessments and align employees with job functions.

        Assess both current employees and potential new hires and then compare the results to the desired ranges. Take the appropriate action based on the strength of the level of alignment. Top performers almost always fit into desired ranges for each critical innate characteristic. If this is not the case, adjust the desired ranges based on the data.

        Other factors should be considered, including the following:

        • When current employees don’t align with their jobs, evaluate other positions within the company that do align well.
        • Openly discuss available options with employees who are misaligned. Develop a plan to shift roles or tweak job descriptions when this is feasible. Frequently, there are other employees who’d be thrilled to trade positions – or even some duties – that better match their own innate characteristics.
        • For applicants applying to open positions, only interview the people who align well with the desired innate characteristics. When people are interviewed who don’t align, there may be a temptation to discount the assessment results. This rarely ends well.

        In the end, the most important job of management is to maximize the return on investment of its workforce. Peter Drucker said, “The task of a manager is to make people’s strengths effective and their weaknesses irrelevant.”

        The most important thing a leader can do is to put people in a position to excel rather than get by or fail. How are you doing in your most important task?

        Brad Wolff specializes in workforce and personal optimization. He’s a speaker and author of People Problems? How to Create People Solutions for a Competitive Advantage. As the managing partner for Atlanta-based PeopleMax, Wolff specializes in
        helping companies maximize the potential and results of their people to make more money with less stress. His passion is empowering people to create the business success they desire, in a deep and lasting way. For more information, visit
        www.peoplemaximizers.com.

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