Perfect Binding

Introducing the New Perfect Binder Sirio

January 5, 2024

Press release submitted on behalf of Meccanotecnica Group

Meccanotecnica Group, one of the leading companies in the manufacturing of industrial book-finishing machines, is delighted to introduce the highly anticipated Sirio Perfect Binder, a groundbreaking advancement in bookbinding technology. This cutting-edge solution provides unmatched efficiency, precision, and versatility while producing high-quality, perfect-bound books in short or ultra-short runs.

The highest performance in its category
The Sirio Perfect Binder is the most productive in its category for ultra-short runs and book-of-one production.

The unique and patented drive system disengages the three independent clamps at the loading and unloading stations without stopping production. At the same time, book size adjustments are automatic, eliminating the need for manual operation. This level of automation and performance leads to a whole new level of productivity and guarantees the utmost production efficiency.

The binder runs at a maximum speed of 1350 cycles per hour with an effective production of ultra-short runs of 1090 books/hour.

Heavy-duty binder for 24/7 production environments
SIRIO is a 3-ton binder built on a stable, rigid, heavy frame. This design guarantees higher precision processes and a longer machine lifespan.

Versatility
The binder processes the broadest range of book sizes, up to 430 mm (17″) of spine length and a thickness of 60 mm (2 3/8″). This format range allows the binder to process most book sizes, representing another unique industry feature.

Premium production quality
The Sirio Perfect binder offers several distinct features to ensure the highest book quality.

Each station has been designed to set a new standard in the category: the jogging table, the clamps, the milling tool, the glue application systems, the creasing shafts, the finishing press, and the unloading station have unique features that positively affect the final product quality.

Gluing systems
SIRIO uses EVA and PUR gluing systems. Side glue is applied through nozzles.

Ease-of-use
The Sirio binder has advanced computer hardware and software, significantly extending its lifespan. An industrial PC controls its functions, while a 17-inch touchscreen monitor presents all data graphically for a user-friendly experience. This interface enables straightforward operations, quick setup, and minimal training requirements.

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 Machines – What to Know Before Purchasing

March 12, 2021

PostPress

When it comes to investing in new equipment, it is always crucial to do a lot of research and ask the right questions before purchasing. No matter the industry, no matter the equipment, it is better to be overly diligent rather than risk possible setbacks and loss of product or profit. To that end, PostPress recently sat down with Bob Flinn, director of business development for Standard Finishing Systems, to discuss what operators should know and look for when it comes to purchasing new perfect binding equipment.

What questions should binders ask when selecting a new perfect binder?

Some binders are designed for high-volume production environments while others are better suited to small- and medium-sized shops. Whether the binder has a continuous print engine or a cut-sheet print engine, the type of perfect binder needed will be dependent on several factors, including: the type of work being produced, the number of print engines, the production environment, the speed of the print engine, the turn time for each job, job volume, overall workflow and run lengths.

With this information, operators will have a better idea of whether a single-clamp or a multi-clamp (high-speed) binder is the best fit. For example, in the case of high-volume applications with limited variability, a multi-clamp binder may be the best fit. However, for high-volume short runs or book-of-one production, it may be more efficient to have two single-clamp binders rather than one multi-clamp binder. When evaluating perfect binding solutions, buyers should make sure to discuss their print environment and needs with their sales consultant.

Are there specific features to look for when working with digitally printed materials?

Those working with digitally printed materials should look for perfect binders that have been designed for this new era of digital print and book-of-one production. Older generations of perfect binders do not come equipped with the level of automation needed to keep up in digital print environments.

The rise of digital print production has coincided with the continued increase in demand for personalization and customization in courseware, photobooks, on-demand novels and more. This has shortened run lengths and increased the level of variability from job to job. Without automation, shops can run into massive bottlenecks in the finishing process because of the increased number of changeovers required to produce this type of work.

If already in a digital print production environment or if there are plans to move in that direction, companies should look for perfect binders with automated, on-the-fly set-up via barcodes and/or calipers to meet the increase in book-of-one and short-run book production.

Which paper stocks work best for perfect binding? What stocks are best to avoid?

Choosing the right substrate for perfect binding depends on a number of factors, such as the type of perfect binder purchased, usage and stylistic concerns, as well as simple best practices. For example, there are several perfect binding methods, such as EVA (hot melt) binding, PUR (polyurethane-reactive) binding, notch binding and sewn softcover binding.

If the binder is using EVA binding, it will perform quite well with non-coated stocks, such as bond, vellums, text and book stocks. Coated stocks and printed pages that have printing or coatings running into the gutter will result in a good-looking product, but the binding strength of EVA with these stocks will not meet industry standards.

If the binder is looking to do PUR binding, the range of stocks that will yield good results includes coated papers, heavier weight substrates, photo paper and even some synthetic materials that can be seen in field manuals and medical applications. PUR lends itself to a strong, flexible and lasting bind even with stocks which are “closed” or yield less paper fiber to which the glue can adhere.

Sewn softcover binding is the combination of machine-sewn signatures and hot melt binding. This method will produce a long-lasting binding with coated or non-coated papers. However, it typically does cost more and takes more time to produce than other methods. Additionally, the need for folded signatures means that this method is not well suited for many digitally printed products.

Finally, much like sewn softcover, notch binding uses a special notching process during the signature folding, in combination with EVA binding, to improve the binding strength of a softcover book. This is not a common method in today’s market, but it does produce a stronger bind for EVA adhesive even when using coated stocks.

How can operators cut down on rejects and waste in the binding process?

Today, automation is the key to reducing waste and rejects. The latest generation of perfect binders come equipped with barcode readers and inline integrity solutions that can perform sheet, signature and book-block-level tracking, as well as cover-to-book-block matching.

Depending upon the configuration, these systems can reject incomplete book blocks or book blocks with the pages out of order, catching and removing errors before they become a problem. To go even further, the rejected book then can be identified via barcode and used to generate a reprint file – all without operator intervention.

Or, if there is a situation involving a mismatched cover and book block, automated binders can alert the operator for correction or ejection. Automated inspection systems like this are integral to reducing waste in the perfect binding process.

Some in the industry still are wary of automation. The first generation of automated machines had steep learning curves and raised questions about quality and integrity. Luckily, those days are long gone. Automation today is much more user friendly, more accurate and extremely reliable.

Furthermore, it already is an essential component of every other production process, from order entry to pre-press to printing. At this point, it is essential to have automation in finishing to keep pace. In the case of continuous print, this is of even greater importance. Higher production speeds mean that recovery from an error and/or downtime can be more costly compared to cut-sheet.

PostPress would like to thank Standard Finishing Systems for its assistance with this article. For more details on the company’s perfect binding and other finishing equipment, visit www.standardfinishing.com.

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.

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.

PUR or EVA – What is the Best Adhesive Option?

December 28, 2018

Information provided by Duplo USA Corporation and BC Adhesives

It can be tough for binderies to decide which adhesive to use in their manufacturing process. The industry seems to be very comfortable with ethylene-vinyl acetate (EVA) since it’s been around for so long, but as polyurethane reactive (PUR) becomes more popular, it is important to know the differences between the two.

Each has different qualities that might make it the correct option for different types of books.

PUR adhesive has many advantages and is becoming more common among customers as a requirement to be used on their books. PUR can bind varnished, UV-coated, carton, mylar and other difficult stocks, where EVA adhesive may struggle with certain coatings or substrates. PUR also is a great choice for digital printing because this type of adhesive isn’t affected by ink migration. It is also a great option for tough papers, cross-grained stocks and higher basis weight recycled papers.

Difficult substrates aren’t the only reason to use PUR: It makes for a higher quality book with excellent flexibility and lay-flat qualities, especially for larger books. Page pulls are usually 40 to 60% higher than when using EVA. And, for most applications, less PUR adhesive is needed, which helps decrease the possibility for adhesive to creep out during the nipping process.

Be cautious when opting for the PUR route, because equipment is going to be more costly and require more maintenance. Since PUR cures when it comes into contact with air, the system needs to be sealed every night. That can be done by applying grease to the nozzle and pot. Failure to complete this step could lead to curing throughout the system.

Another concern with PUR is the MDI (diphenylmethane diisocyanate) emitted during the curing process. This can be emitted as vapor or aerosol and can cause allergic reactions to the skin or respiratory issues. MDI levels drop drastically once substrates are joined, so this is mainly a concern during preventive maintenance. There are tools to test the MDI levels in a facility. These levels can be lowered with venting and other techniques. Finally, the curing time for PUR is much longer than for EVA; it is common for binderies to wait a full 24 hours before shipping finished books.

EVA is a great option for more standard operations. The handling of this adhesive, along with maintaining the system, is much easier than with PUR. Binderies can move much faster when using this product due to the fast curing time. EVA has very quick set points that allow for a short cure time, meaning faster turnaround for trimming and the finished piece.

EVA also is a much more cost-effective option for both the equipment and the adhesive itself. Milling is still extremely important when using EVA, but it’s not as much of a factor as when using PUR. Binders using EVA can notch bind their books. This means that small notches are cut into the spine and filled with glue before the cover is applied. This is not recommended for PUR applications. PUR needs the peaks and valleys of the fibers across the entire spine to succeed. Overall, EVA hotmelt glues still have their place in book-binding – especially when binding thread-sewn books – as the thicker glue allows for greater penetration into the spine area of the folded sections.

In summary, both processes are still widely used within print finishing and bindery operations. The question of “which is best?” needs to be replaced with the question “which is most suitable?” The decision to use one over the other is job-specific and involves numerous considerations – from substrate used and thickness of the book, to the intended use of the product and financial constraints to produce.

PostPress would like to thank Duplo USA Corporation (www.duplousa.com) and BC Adhesives (www.bcadhesives.com) for their assistance with this article.

Which One is Most Suitable

Advantages of PUR adhesives

Aggressive adhesive for coatings, digitally printed stocks, other tough surfaces
Isn’t affected by ink migration
Excellent flexibility and better lay-flat qualities
Use less adhesive – less likely for adhesive to “creep”

Advantages of EVA adhesives

Runs on less costly machinery and less maintenance on machinery
No concerns with the MDI (diphenylmethane diisocyanate) emittance
Much shorter curing time for faster turnarounds
Less costly adhesive and best choice for many standard applications

Q&A: Perfect Binding – Traditional EVA vs. PUR Adhesive

June 14, 2017

by Brittany Willes, editor, PostPress

Perfect binding and PUR binding – they’re essentially the same process, aren’t they? Actually, no. PUR binding refers to a method of perfect binding that has become increasingly popular in the last few years. As with traditional perfect binding, a book’s pages and cover are glued together at the spine while the three remaining sides are trimmed to give them the classic “perfect” edges. However, there are a few notable differences between the two methods.

With decades of industry experience, Eckhart & Company, Inc., Indianapolis, Indiana, is more than familiar with the challenges faced by printers and binders looking for the most effective method for binding a given project. When it comes to deciding between traditional perfect and PUR binding, Chris Eckhart, president of Eckhart & Co., offered the following information:

How is PUR different from perfect binding?

For sure there are differences between the two binding methods, even if it doesn’t appear that way at first glance. It all comes down to the adhesive used during the binding process. The biggest difference between PUR and perfect binding is that traditional perfect relies on ethylene vinyl acetate (EVA) adhesives, while PUR makes use of polyurethane reactive (PUR) adhesive.

Book spines that make use of PUR are prepared in much the same way as a traditional EVA-bound book, utilizing a variety of notching, roughing/equalizing heads in order to create fiber. The adhesive then will bond with these fibers during the curing process. The properties of PUR adhesive are designed in such a way that they draw moisture out of the air as part of the curing process. The amount of paper fibers also is reduced with PUR.

Why opt for PUR instead of EVA binding?

One of the biggest advantages of PUR is that it offers significantly increased binding strength. Once the adhesive has set, page pull tests are often up to 50 percent stronger than with books that use EVA glue. It also offers greater aging stability, is impervious to print ink oil migration and is capable of bonding to coated and cross-grained stock. Furthermore, PUR is extremely durable. This is particularly helpful in that it is not susceptible to issues brought on by extreme temperatures, like traditional perfect binding can be.

As with conventional hot melt glues, the initial bond in PUR is formed as it cools and solidifies. Unlike conventional hot melts, PUR contains reactive components (isocyanate groups), which cure in the presence of humidity and form a strong elastomeric film. Furthermore, while EVA’s properties allow it to be reactivated with heat, the film produced by PUR cannot be re-melted and is insoluble to most solvents. Thus, EVA binding exposed to extreme heat is able to melt, while a PUR binding will remain in its solid state. Typically, PUR has a heat resistance of 350°F peel failure, compared with 165°F to 200°F for quality EVA. Extremely cold temperatures provide additional problems for EVA, mainly that it is subject to cracking and brittleness. Again, because PUR cannot be reactivated, it is in no danger of cracking. Typical cold crack for PUR measured at -20°F vs. 30°F for EVA.

How does PUR achieve its flexibility?

As mentioned earlier, once the adhesive is set, it is extremely difficult to pull pages from a PUR-bound book. The adhesive cannot be reactivated, giving it increased durability. This might seem like it would make the binding less flexible, but that’s not the case.

PUR uses a much thinner application of adhesive than compared with EVA (10 to 12ml vs. 25 to 35ml per EVA). This thinner application of adhesive, along with its reactive properties, is what gives PUR its flexibility. In testing, PUR has extremely high flex-test values, often in excess of 1,000 flexes. It is this flexibility that allows also for greater lay-flat characteristics. When applied properly, PUR’s lay-flat ability is comparable to that of true Otabind. Additionally, a thinner application frequently will improve performance and result in improved “mileage” over time. With less adhesive on the spine, there is less distortion of shape and cleaner overall appearance.

What are some challenges associated with PUR binding?

PUR is applied using an open roller pot system and, while this system does have advantages – such as better accessibility for operators and providing greater consistency of application with thicker books – it also can be costly in terms of maintenance and cleaning.

The one-pot system requires a longer cleanup process than traditional EVA systems. The pot must be drained and the adhesive allowed to cure overnight before the pot can be reheated and any remaining adhesive removed. The adhesive pot may require recoating as often as once every three years. The system also allows for greater amounts of glue spoilage.

When it comes to maintaining a one-pot system, it’s best to check with the equipment manufacturer for guidance on best practices. The technology does exist to apply (essentially spray) PUR onto the binding edge using slot-nozzle technology. This technology has advantages and disadvantages – the biggest advantage being the cleanup is not nearly as extensive as it is with an open pot system.

Are there times when PUR adhesive is not preferable to EVA?

In almost every situation, PUR is better than EVA. There is one exception, however: If a book block is being bound or prepared for case binding, the spine can’t be rounded in the casing-in process if PUR is used. In this situation, EVA has a tad bit more roundability/flexibility.

PostPress would like to thank Chris Eckhart, Eckhart & Co., and Matt Worley, BC Adhesives, for their assistance with this article. Eckhart & Co. has spent decades providing the printing industry with bookbinding and custom information packaging. Based in Franklin, Wisconsin, BC Adhesives combines its technical expertise with ongoing, proactive support to ensure its customers are utilizing the most efficient consumption practices to help customers maximize the efficiency of each application.

Challenges in Perfect Binding

May 20, 2013

by Jen Clark, The Binding Edge

Employees insert items into books that were perfect bound at Pacific Bindery.

In the last decade, declining run lengths and quicker turnaround requirements have left little room for error in the bindery. Long-standing binding methods, including perfect binding, have had to evolve because offline production machines and shorter turnaround periods result in expensive short-run applications. Recent innovations in machinery have made the process of completing a printed book much more efficient, which saves time and expense. But that same technology also has brought challenges for binderies trying to keep up – not only with the technology, but the competition as well.

Printing with digital technology is an economical and efficient way to disseminate information, but digital printing has had an effect on all aspects of bookbinding, said David Reindl, president of Reindl Bindery, Germantown, WI. “In perfect binding, many small run jobs have switched from offset printing to digital printing,” he said. “Many printers with digital printing capabilities also can bind the smaller quantities, taking work out of our shop.”

Some digital printers, especially those that are relatively new to the print industry, don’t have a strong understanding of bindery, said Kris Bovay, general manager of Pacific Bindery Services Ltd., Vancouver, BC, Canada. One of Pacific Binderys clients is an architectural firm that prefers to print its content in-house, but then sends the documents to Pacific Bindery for binding.

“They are not printers by trade – they are architects,” she said. “Working with them to produce their bound books requires more assistance and training than would be necessary if our client had hired a printer to do the work. However, with the entry of affordable digital print equipment, some customers like the flexibility of doing some of the work in-house.”

Roswell Bookbinding educates its clients on the 12- to 24-hour drying period required with PUR glue.

Mike Roswell, president of Roswell Bookbinding, Phoenix, AZ, agreed. “The learning curve steepens with the lack of experience,” he said. “Trying to educate a novice is difficult at best, especially trying to convey specifications that require terminology that they have zero experience with. The ability to educate and inform the client has a direct effect on how smoothly the job runs.”

For example, he noted that digitally-printed books that come in as pre-collated book blocks make feeding more difficult, especially on perfect binders that are designed for signatures. But Reindl pointed out the biggest challenge that digital printing presents has to do with the ink used, which has a direct effect on the type of adhesive binders should use. “We need to consider the proper adhesive when binding any digital product,” he said, adding paper quality is another concern.

“Paper quality is not as good as it was in the past,” Reindl said. “Choosing the proper adhesive for binding these difficult stocks can be very challenging.”

Since there is no ink absorption with digitally printed books, that creates many issues – especially with hardbound books, Roswell said. “Since the text cannot absorb much moisture, it tends to go directly into the cover, which creates the potential for warping. Softcovers have not been as much of a problem,” he explained.

Bovay agreed, noting some digital processes leave an oily film on the sheet that interferes with the gluing process. “One solution is to bind those books with polyurethane reactive (PUR) glue both on the spine and on the side. However, not all binding equipment has that capability,” she said.

For binderies that deal with many different kinds of stock papers, PUR is the best adhesive option. “PUR allows us to create solid bonds on nearly all paper types,” Reindl said. “In fact, we are able to bond directly to coatings and some plastics.”

Added Bovay, “The challenges the industry faces in working with adhesives for perfect binding is really tightly connected to changing substrates, inks, solvents, varnishes and coatings and other inputs that can affect the chemistry of the adhesive. We’ve found that for the most part, PUR is the most successful adhesive for a variety of uses; however, working with PUR has its own challenges in terms of operating efficiency.”

Roswell noted that since the advent of PUR, his company has had little problem with adhesion. “It’s been minimal,” he said. “We don’t have much difficulty with adhesion. The only problems in using PUR are the expense and curing time. Some clients do not understand that the book is not usable for a period of 12 to 24 hours until the adhesive has cured.”

Perfect bound books require adequate binding strength to prevent the pages from being pulled from the binding. Spine preparation and adhesive choice is critical because inflexible adhesives can result in books not lying flat, and the spines often can be distorted with repeated use. “The newest machines do a much better job of preparing spines for whichever adhesive the bindery is using,” Reindl said. In the last two years, Reindl has installed Kolbus’ newest perfect binding machine. “Quality and run rates improved immediately.”

Roswell said manufacturers have developed more equipment geared toward handling pre-collated, short-run jobs, “and we have purchased one,” he noted. “We will be installing another short-run binder with PUR in the coming months.”

Pacific Bindery has a 21-pocket Muller Martini Corona binder with PUR and lay-flat capability, an 18 pocket Muller Martini Starbinder and a Horizon BQ for short-run work. “Our five-year capital expenditures plan includes a commitment to changing some of that binding equipment to better integrate with anticipated changing customer needs,” Bovay said.

Perfect binding, according to Bovay, is in the mature phase of its life cycle. “There is a growing market for short-run, self-published books, whether those publications are photo books, journals, diaries, etc. Within that market, there is a need for perfect binding, along with casebinding,” she said. “There still is a market for perfect bound magazines, books and even catalogs.”

In the last couple of years, catalogs, for example, have fallen out-of-fashion, but Pacific Bindery has noticed a change-of-heart from clients. “They had stopped producing print catalogs and went online,” she said. “Those customers came back after finding that their sales dropped with only online media delivering the sales and marketing messages. Now, they are doing shorter, more targeted print runs that complement the online marketing efforts.”

Roswell said there is no reason to believe the steady decline in perfect binding volume over the past 10 years will not continue. “Annual reports, statistical abstracts and many other single-color publications have either disappeared or grown smaller,” he said. “The influence of technology seems to be the reason for this and does not appear to be stopping any time soon.”

But, while technology and attitudes may change, Reindl and Bovay agreed that perfect binding always will have a place. Roswell believes that long-run perfect binding has peaked and runs will continue to shorten. “It will not disappear completely, and I think that the demise of the book in general has been greatly exaggerated,” he said.

Investing in new technologies is the key for binderies to “win the race,” Reindl said. “Those companies will be able to offer better quality in less time and at lower prices.”

The reality is that binderies need to keep looking for new partnerships and services that complement their existing capabilities and provide stronger opportunities for growth, Bovay said. “That commitment to adapting and evolving will enable us not only to survive, but also to grow,” she stated.

Added Reindl, “Those companies that don’t or can’t invest in the future will more than likely be left behind or will just go away.”

The Binding Edge would like to thank David Reindl, Reindl Bindery, Germantown, WI; Kris Bovay, Pacific Bindery Services Ltd., Vancouver, BC, Canada; and Mike Roswell, Roswell Bookbinding Phoenix, AZ, for contributing to this article.

Perfect Binding for Digital Print

August 21, 2011

by: Steven Calov, Heidelberg USA

In the finishing realm, perfect binding plays an important role in promoting efficient operations and fast turnarounds as the market moves toward digital print. As print becomes more prominent as a marketing piece, short-run perfect binding is becoming more desirable, compared to stitched products.

Speaking of digital print, its suitability for short and ultra-short runs and smaller formats is a given; however, there is more to the story, based on changes in the marketplace that have revised traditional thinking about short-run approaches to the finishing of digitally printed output.

The market dictates the pace of change, moving toward shorter print runs and faster delivery times, as well as a leveling of the playing field between the finishing of conventionally and digitally printed products in the smaller (20″) formats that are currently digital’s sweet spot. In this new environment, printed materials arrive ready for finishing off a variety of output devices, while finishing requirements are being met with a variety of in-, off- and near-line solutions, depending on volume and whether the aim is to print one or 1,001.

Digital Dollars

Like digital printing, digital finishing is driven by performance, quality and cost. Some digital printing devices are equipped with finishing units capable of performing binding and finishing functions – including perfect binding – in-line. This makes the process of printing a complete book more efficient because it eliminates a material handling step from the workflow, sparing time and expense, but it also can limit an application’s variety and production speed. However, the need to provide fast, inexpensive finishing of digital work using traditional equipment built for offset calls for results-oriented solutions that will add quality and value to the printed piece, bring cost efficiency to bear on the finishing process and keep profit margins high.

Perfect or adhesive binding is a method of binding single sheets – as opposed to signatures – into a book. Many digital books are printed as stacks of single sheets. One of the most easily automated of finishing processes, perfect binding’s low cost makes it a popular choice for binding a variety of printed matter, wherein single sheets are gathered, stacked and the binding edge covered with glue. A cover is attached to the book and is held in place by the glued spine. Then, the entire product is three-side trimmed on a dedicated trimmer or guillotine cutter.

Professionally perfect-bound books have square backs, smooth spines and adequate adhesive strength to prevent the pages from being pulled from the binding. The only way to accomplish this used to be with large off-line production machines, which required lengthy makereadies and resulted in expensive short-run applications. The larger off-line perfect binders were better suited to longer print runs. In recent years, however, a combination of factors has prompted printers to seek out small-format standalone perfect binders to accomplish low-volume, short, ultra-short and one-off run digital work in-house. These factors begin with the rise of specialty print products, such as digital photobooks, and extend to commercial printers offering custom and on-demand services to their customers. Rising transportation and delivery costs also have played a role in the shift to in-house production.

Designed for Digital

An alternative to large off-line binding devices are smaller, economical, off-line perfect binders, which are compatible with or specifically designed for small digital print applications and have the capability to produce perfect bindings that are of nearly the same quality as the bindings produced with the larger machines. The overhead cost is much less than the larger machines and makeready times are greatly reduced.

Solutions answering these needs are modular, flexible, integrated, run at speeds as fast or faster than the output device and offer multiple opportunities for reductions in labor, including quality verification. They are easy to operate and quick to set-up for new jobs, and, last but not least, feature connectivity and JDF. They are machines that can handle books from digital printers and offset presses and perfect bind books of one or 1,000 quickly, efficiently and profitably.

A Sticky Wicket

Are there challenges presented by the perfect binding of digital print? Yes. Among the biggest are failure to form a durable adhesive bond on digitally qualified papers, as well as the potential cracking of inks and coatings. In particular, the presence of fuser oil left on digital sheets can have a severe impact on the pull-strength of a digitally printed, perfect-bound book when hot-melt adhesives are used. Toner can have the same effect if the printing bleeds into the spine of the book.

For these reasons, the perfect binding of toner-based color sheets using conventional hot-melt adhesive has been largely supplanted by the use of polyurethane-reactive or PUR adhesives on fast-makeready binders such as Heidelberg’s entry-level Eurobind 600 PUR. This machine features Heidelberg’s unique nozzle application system, which takes the convenience of PUR glues for adhesive binding of digitally printed materials one step further by minimizing (expensive) PUR glue exposure, giving a more consistent glue line on the cover of the book, and saving time and money over open tank systems. While PUR is more expensive than traditional hot-melt adhesives, it also lasts longer, weathers extreme temperatures, looks good and holds difficult plastic or coated stocks reliably. PUR technology ensures reliably high adhesion to the sheet edges so finished products can be opened flat without problem, even with difficult materials such as heavily coated papers and digital print products.

But don’t count hot-melt down and out just yet. While PUR provides an added measure of safety that the job will not be rejected, it also adds significant cost. Given the recent migration to inkjet and oil-less fusing of toner based products, however, hot-melt glues can provide a more cost effective solution as long as the spine preparation is sufficient to result in good book adhesion (good pull results). At least one perfect binding operation in a digital print environment we know of has spent effort to prepare the spine very well in combination with hot-melt glue to produce excellent results. It will be interesting to see whether PUR or hot-melt “wins” in the coming years, or whether both will share this space.

A Trimming Dilemma

We also should mention trimming. Trimming is accomplished with either a dedicated three-knife trimmer or a guillotine paper cutter. The issue with three-knife trimming is that the capital cost for the machines is most often above $100,000 US, while the quality of trimming delivered by machines currently on the market often is not up to market expectations, due to spine knicking. A cost-effective alternative is to use a guillotine cutter instead, even though it adds another material-handling step to the process. Heidelberg has studied the problem and found that at quanitities up to 1,000 books per hour, the cost and productivity of guillotine trimming can be advantageous. Over the very short run, the challenge is to reduce the makeready of the cutter from book to book size, so equipment suppliers are exploring ways to add automation to the cutting process. By sending the cutting parameters to the guillotine at the point of prepress, or by using a bar code on the book to load the cutting parameters, the cutting process can be sped up substantially while reducing re-runs and waste.

Seize the Day

Short-run perfect binding today denotes not just shrinking order quantities, but also foreshortened turnarounds and product flexibility demanded by customers who now have the option to produce low-cost books in the quantities – as small as one – they need. Manufacturers of finishing equipment are seizing the opportunity to fine-tune their equipment to handle the requirements of digital output. As mentioned above, today’s high-speed automated perfect binding machines can execute digitally printed, perfect-bound books in in-line, off-line and near-line configurations (useful in cases where the binder runs faster than the output device). Lift-type deliveries are designed to ensure superior glue stabilization and gentle transport of the book block in different production environments.

Automated components are designed to facilitate the adjustment of clamp opening widths; integrated pressing, scoring and spine preparation; gluing length control and more. Meanwhile, the addition of exchangeable hot-melt and PUR glue tanks, variable clamps, self-calibrating missing sheet detectors and graphical touchscreen controls for shorter set-ups, lower waste and faster turnarounds mean that top-quality, digitally printed, adhesive-bound products can be produced quickly and economically on traditional perfect binding equipment from offset or digital streams, with disparate jobs ganged together for maximum efficiency.

Advances in finishing automation are being driven by the rise in digital printing, characterized by declining run lengths, quick turn requirements and the need to train workers quickly. As run lengths get shorter, set-up time becomes a bigger percentage of the total job time, driving up the labor cost per unit produced. Because traditional equipment built for offset printing typically requires more makereadies for digital work, regardless of run length, the reduction, elimination and/or automation of costly extra steps is an operational imperative. The goal? The ability to finish digitally printed output at high speeds, in real time, with no waiting, at the highest quality.

Steve Calov is postpress product manager for Heidelberg USA. A leading solution provider for the print media industry, Heidelberg manufactures precision printing presses, platesetters, postpress equipment and software for integrating all printshop processes. For more information, visit www.us.heidelberg.com or call 770.419.6500.