Clam Shell Boxes

What is a clam shell?  In the context of a bindery a clam shell is a one-piece box. Like a set-up box it does not collapse. A clam shell box can be almost any size, made of a wide range of materials and have “insert configurations” that can be functional, visually appealing and creative.

Clam Shell

The quantities we have produced range for 3 to 10’s of THOUSANDS.  Clam shell boxes are made of course to show something. The commonest use is to hold a book. The next most frequent use would be HOUSE a diploma, very special brochure or PERSONALIZED piece. The third most requested would be a retail product.

Clam Shell

Clam shell boxes can have “MANY” different styles of closures; the commonest being a magnet. These boxes are “decorated” with either a debossed/ emboss style of printing followed in frequency by foil-stamping followed in frequency by a Litho printed case wrap.

Clam Shell Boxes

 

Clam Shell Boxes

Again, I’ve sent you lots of pictures to give you some ideas regarding clam shell boxes…… ideas to let your imagination flow.  Almost all clam shell jobs we produce follow the same course in almost all cases the client meets with us to look at our INCREDIBLY large range of samples and after discussing what is to go into the clamshell boxes we establish sizes, closures, types of material, liner details, “decoration”, type styles, production time and pricing.  In almost all situations we make a prototype (which we charge for) which usually takes 3- 5 days.

Clam Shell Boxes

 

Clam Shell Boxes

Clam Shell Boxes

Features

  • Solid
  • Light

Benefits

  • Functional; eg holds some thing
  • Durable
  • No instructions needed for usage

Factors to consider

There of 100’s of creative options to choose from so consider time for production and usage required

Book & Box Closures

The following images in this email show only 10 out of the dozens of types of closures for books and boxes. Hopefully, this email will give you some ideas for ways to make your project unique. Each of the types of closures featured can range from being very inexpensive (Velcro fasteners in first image) to being very pricey (combination lock in the second image).

Book and Box Closures

Book and Box Closures

The following image is a button closure that has an elasticized loop that stretches around the button.

Book and Box Closures

Next, is a flexible die cut magnet that wraps half way around the book cover. The back cover has an implanted magnet inside.

Book and Box Closures

The next image shows a faux leather strip and metal post closure.

Book and Box Closures

The image below shows a box with an elasticized loop that is riveted to the bottom. The loop is hooked over slits made in the top of the box.

Book and Box Closures

The next image shows an oval rivet that slides over a flat metal head that, when twisted 90 degrees, holds the box closed.

Book and Box Closures

The box shown below was a project for Neenah Paper. The box is closed with a Velcro-lined flap of polyurethane.

Book and Box Closures

This last image shows dome snaps, which are often seen on articles of clothing.

Book and Box Closures

Features

  • Virtually an endless range of styles, textures, materials, colours, etc.
  • Range of prices

Benefits

  • Easily keeps books and boxes closed when desired and easily opened.
  • A final touch to a piece that can be that WOW factor

Metal Etched Plates

What do Metal Etched Plates have to do with binderies and books? We put them on binders and books instead of doing foil stamping, printing, embossing/debossing or screen printing.

Metal Etched Plates
Metal Etched Plates

The metal can be aluminum, tin, brass or steel. We mounted plates ranging in size from 1/2” x 3/4” to 11” x 14”, there is a huge range!

Metal Etched Plates

Metal Etched Plates can be attached to binder and books by three methods:

  1. Gluing
  2. Riveting
  3. Pinning

The following two images show a ring binder that has an aluminum plate that is both etched and screen printed.

Metal Etched Plates
Metal Etched Plates

The next two images show plates that are both etched and coloured.

Metal Etched Plates
Metal Etched Plates

This next two images show “pin pieces.” We drill 2 small holes into the cover, insert and bend the two prongs inward and line the book lid or book cover to hide the prongs.

Metal Etched Plates
Metal Etched Plates

The following image shows an etched brass moulded piece.

Metal Etched Plates

One supplier we found can, in addition to etching and decorating metal plates, can also personalize each plate with a unique name. The per unit price was surprising low! In some instances, the supplier can personalize 500 unique names cheaper than we could foil stamp 500 unique names!

Features

• Multiple shapes, textures, surface and metals
• Can be both etched and coloured

Benefits

• Very distinctive
• Great value added benefit
• Can be personalized, sometimes at a cheaper cost than foil stamping!

Setup Boxes

What is a Setup Box? It is simply a box that cannot be collapsed and is very sturdy. There are fundamentally two styles of boxes: Setup Boxes and Folding Boxes. An example of a Folding Box (see image of flattened white box below) is the box your tube of toothpaste came in. Folding boxes are just one pieces and are produced at rates of many thousands per hour. Setup Boxes, on the other hand, have a top and bottom and are produced at a much slower rate as the process relies more on hand assembly.

Setup Boxes

We make Setup Boxes but only in unusual sizes and small quantities. We’ve made Setup Boxes as small as 3/4” high x 2” wide x 2” deep and as large as 8” high x 9” wide x 16” long! We can produce virtually any size of Setup Box – generally, size isn’t an issue for us!

Setup Boxes

Setup Boxes

Setup Boxes

Setup Boxes

We can produce Setup Boxes that are wrapped in litho printed sheets, paper, cloth, faux leather and foil. We have even wrapped Setup Boxes in plastic film laminate! We can add foil stamping, duplexing and debossing to Setup Boxes.

Some ideas for what can go into Setup Boxes are pencils, pens, shows, jars, bottles, cutlery, tools, etc.

Setup Boxes

Setup Boxes

Setup Boxes

Setup Boxes

Features

  • Square, permanent corners
  • Has a separate base and lid
  • Sturdy and durable
  • Can’t be collapsed

Benefits

  • Permanent box shape
  • Users know how to open & close the boxes and don’t need instructions

Factor to Consider

  • If your box is to be wrapped or mounted with litho-printed paper, we need to specify sheet sizes and print positioning

Embroidered Book Covers

Embroidered Book Covers … wow! They are unusual, distinctive and memorable.

The image below (I wish the book would photograph more effectively) shows a book spine and front cover with raised thread embroidery! We can produce Embroidered Books using literally hundreds of colours of thread; shiny or matte, fine or bulky, multiple levels with multiple colours.

Embroidered Book Covers

When you consider thread embroidery for your project let your imagination really wander. The two images below show multiple colours of threads.

Embroidered Book Covers

Embroidered Book Covers

The image below shows a single ply embroidered cover of a saddle sewn book.

Embroidered Book Covers

The image below shows a square back bound book with a five-coloured patch/label securely glued to the front cover.

Embroidered Book Covers

This pink coloured book shown below is a four-coloured embroidery job that has been embroidered through a very smooth, delicate cloth.

Embroidered Book Covers

The brown book shown below is bound in a round-back, case bound style and has six colours and three different textures of threads.

Embroidered Book Covers

Features

  • Smooth
  • Raised
  • Texture

Benefits

  • Greatly increases the real value of the book
  • The book jumps out, gets noticed and remembered

Factor to Consider

  • Although we have hundreds of different kinds of book binding cloth, adding embroidery to your book reduces your cloth options.

Loop Stitching

What is Loop Stitching? The following four images are the perfect answer.

Loops Stiching

Loop Stiching

Loop Stiching

Loop Stitching

Loop Stitching is a saddle stitch with “loop.” When a Loop Stitched book is open to the centre, it looks exactly the same as a regular saddle stitched book. The outside “loop” on a Loop Stitched book allows the book to be inserted into a ring binder with no drilled holes. The advantage of this is uninterrupted graphics and a cleaner look.

Our Loop Stitching comes in two sizes. The smaller loop size can be inserted into a ring binder with a ring size up to 1”. The larger loop size can accommodate up to a 4” ring binder ring size.

Many jobs that require Loop Stitching are designed to be Loop Stitched, but many jobs are simply to a fix a mistake! Loop Stitching can rescue poor pre-press design, 3-hole drilling that ruins copy or graphics, etc. The books are simply Loop Stitched (instead of being reprinted and bound)!

We can Loop Stitch almost any size, like regular saddle stitched books. The following two images show a new process we have developed. This new process is the solution for a perfect bound book that was meant to be drilled but cannot be because the drilling obscures copy, graphics, prices, etc.

Loop Stitching

 

The solution we developed simply involves taking blank 10pt white stock, creasing and folding it as a 4-page, Loop Stitching it, gluing it closed and tipping it onto the back of a perfect bound book. Presto! You have a Loop Stitched perfect bound book and a problem, which may have required a complete re-print, has been solved!

Features

  • Shiny
  • Smooth

Benefits

  • Books turn more easily in ring binder if they are “loop-stitched” versus drilled
  • Unlike drilled holes, a loop stitch doesn’t interrupt graphics
  • Perceived added value
  • Can be a very important solution to what can often be a very expensive problem

Fold-Outs

Fold-outs are pages or covers that “fold-out” from the main part of the piece like a book, magazine or folder. We’re seeing a huge increase in the number of jobs with Fold-outs! The main reason we’re seeing more Fold-outs is our improved technology and techniques, which have reduced spoilage, improved quality and greatly improved production time. New technology enables us to produce certain styles that we couldn’t do before, all the while lowering prices! That’s what people like to hear!

Fold-Outs

Fold-outs are only for the pages of books. We can often do Fold-out covers for saddle stitched books (e.g. a six panel roll fold on the book cover). Fold-out covers on perfect bound books are another story … it’s extremely problematic, so generally not a good idea.

Fold-Outs

The above collage of images shows a 13” square book with two opposite 4-page Fold-outs that, when opened fully, are 52” wide! If we had done a 1-page Fold-out on the top and another 1-page Fold-out on the bottom, the vertical spread would have been 39” top to bottom! What a great way to show off something tall like a condominium!

Fold-Outs

I’ve been asked whether Fold-outs are cheaper in saddle stitched, perfect bound or case bound books. Simply put, there are far too many variables (quantity, number of Fold-outs, size of book, etc.) to say which style of binding for fold-outs would be the cheapest.  We do, however, see far more Fold-outs in perfect bound books.

Fold-Outs

Features

  • 2 or more panels
  • They can be done on saddle stitched, perfect bound and casebound books
  • Cover Fold-outs can be done easily on saddle stitched books

Benefits

  • Requires user to be more involved with the piece
  • Adds more ‘real estate” for printed copy
  • Differentiates the book
  • Fold-outs helps illustrate wide or tall things like condominiums or vehicles

Factor to Consider

  • If the Fold-out is to be flush with the face, foot or spine, the price goes through the roof! To keep costs down, the Fold-outs should be held back.

Please also see information regarding Saddle Stitching Here!

Tipping

Tipping is the automated process of attaching (or gluing) something such as a card, pouch, folder, etc. to a larger printed piece called a carrier. Eight different trade binderies in Toronto do Tipping, so for regular Tipping jobs, the prices are highly competitive. We only do difficult or unusual Tipping jobs!

Tipping

tipping

Tipping

We have the machinery and expertise to tackle a range of Tag Stringing jobs like:

  1. Tipping 2 or 3 pieces onto one side of a carrier
  2. Tipping a piece onto both sides of the carrier
  3. Tip-ons (as pictured) that are filled with liquid or granular material
  4. We can Tip-on a piece onto the pages of a saddle stitched book. For example, on a 12-page saddle stitched book, we can tip a piece onto each of eight out of the 12 pages!
  5. We can Tip-on products that have jagged or irregular edges
  6. Tip-on to a specialty folded carrier like accordion folders, gate-folds, etc.
  7. Tip-ons that are thicker than 40pt
  8. We can Tip-on to a carrier sheet as large as 40” x 72” and fold and glue the sheet (carrier)!

For tipping that is unusual please call us at (416) 701-0111 ext. 311 or email at quotes@sgfteam.ca. We can help!

Tipping

Tipping

Tipping

Features

  • Tip-on is removable from carrier
  • Piece is flexible

Tipping - Specialties Graphic Finishers

Tipping - Specialties Graphic Finishers

Tipping - Specialties Graphic Finishers

Benefits

  • Effectively gets product samples into customer hands

Factor to consider

  • Consider how the pieces are to be distributed (e.g. mail, bulk, retail, by hand, etc.). Distribution method can affect the strength of glue required.

To see more examples of Tipping please click here. 

TIPPING

Companies that produce consumer products are going to ever-increasing lengths to get samples into the hands of consumers. This is good news to the graphic arts industry because most of the product samples are tipped onto or inserted into a printed piece.

To facilitate this tip-on market, we use high speed, high quality machinery to tip-on a variety of products, from gift cards and shampoo packs to envelopes and coupons.

  • Our machinery glues on and registers many pieces within 1/8″ accuracy
  • The glues we use greatly reduces paper tear when the product is removed
  • We can fold carriers once or twice in-line after tipping
  • We can in-line glue carriers closed or add a clip/wafer seal
  • We can in-line inkjet address carriers and bulk box or post office bag

Die Cut Case Bound Covers

What are Die Cut Case Bound Covers? The following pictures show case bound/hard back books that are Die Cut completely through the front covers. Until recently, this was extremely RARE, but now I’m seeing the Die Cut Cover concept somewhat often.


The Die Cut Cover addition to a case bound/hard back book certainly makes it distinctive! You’ll notice circles, ovals, and rounded shapes.

The Die Cutting portion of the project is done after the book is completely bound. Since the most common board thickness is 100pt, plus glue on two side, plus the end-paper, and the cover wrap, the Die Cutting portion is through a cover thickness of 120pt. Since Die Cutting the Cover is done on such a thick piece, there are some limitations to the complexity of the Die Cut shape. For instance, a star shape or shape with fine points are not suitable. Shapes that are square, triangle, oval, rounded, 5, 6 or 7 sided and maybe certain letters such a B, M or W are suitable.


I have said before that a genius is someone who knows the difference between a fad or a trend. I’m not a genius so I don’t know if Die Cut Covers are a fad or a trend. Most binderies that make case bound books cannot Die Cut the Covers. We have special machinery to do the Die Cut Covers that most case bound/hard back book manufacturers don’t have!


Features

• Smooth edges
• Book Cover is still perfectly flat
• Exposes first page

Benefits

• Possible to have a printed logo or picture show through the Die Cut hole
• Greatly differentiates the book from countless others!

Factors to Consider

• Die Cutting Covers adds 2 or 3 days to all production time for the book production
• Die Cutting Covers adds to the total cost of book production

Wax Seals

What are wax seals? The following pictures tell part of the story. The “wax seal” is coloured wax that we melt onto the printed piece and imprint with a custom made metal die. The metal die is the same kind of metal die we use for foil stamping. The metal die can have on extensive range of logos, words, or type styles etc. The runs are short, from a few dozen to a few hundred. The size of the wax seals can be from as small as 3/8” wide to 1” wide. The wax comes in over a dozen colours, with red being the most common.

Wax Seals

Wax Seals

Wax Seals

Features

  • Bright colours
  • Smooth

Wax Seals

Wax Seals

Wax Seals

Wax Seals

Benefits

  • Each job has a custom made “STAMP” in the wax (e.g. logos, initials, emblems, etc.)
  • Wax seals are distinctive and personal
  • Wax seals greatly enhance the value of a printed piece

Wax Seals

Wax Seals

Wax Seals

Factor to Consider

  • While this process is expensive, wax seals add the perception of prestige and uniqueness to a product

Specialties Graphic Finishers

INNOVATIVE BINDING & FINISHING SOLUTIONS

We are Canada’s premier graphic finishing house. Recognized on both sides of the American-Canadian border for our quality and service, we have consistently been the leading recipient of many industry awards.