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.

Giant Grommets

I hear a constant refrain from customers . . . “Show me something different!” Well, I’m happy to oblige by showing you pictures of something that’s truly different . . . Giant Grommets! As you’ll see in the following images, Giant Grommets come in numerous colours and 9 different diameters. A book bound with Giant Grommets really stands out!

Giant Grommets

Giant Grommets - Book Binding and Finishing

Features

  • Smooth
  • Always made of metal not plastic

Giant Grommets - Book Binding and Finishing

Giant Grommets - Book Binding and Finishing

Benefits

  • Permanent so you can’t remove papers
  • Long lasting and durable binding method (as in decades!)
  • Grommets are by and large scratch resistant

Giant Grommets - Book Binding and Finishing

Factors to Consider

  • Consider placement of printed copy so copy or borders or pictures are covered by the grommets
  • Giant grommets are limited to book thickness up to 3/8”

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.

Anstey Book Binding

Anstey is the epitome of low-tech and old-fashioned. We believe in the hand in “hand-crafted” and are proud to use traditional and innovative binding and finishing techniques.

Chipping – Specialties Graphic Finishers

Here’s another odd ball word, “Chipping”. (No, I don’t make up these names!). Chipping is the process of applying samples of paper or something similar in multiple positions to a heavy stock weight paper carrier. If you’ve ever picked out paint samples at a store, you probably collected a few booklets with paint chip inside.

Chipping

Chipping

Chipping

Chipping is unique compared to other common processes of gluing on samples. Any time you see multiple pieces of material thicker than paper such as tile, wood or rug, the production method is different than Chipping. The production of heavier samples always involves the applying of patterns of glue to the carrier and then the sample pieces are applied (usually automatically) to the wet glued squares.

Chipping

Chipping

As for Chipping, the glue is applied to the bottom of the paper sample itself and then the multiple pieces are applied in one pass to the carrier. Paper companies require Chipping for quality issues because if one of the tiny paper samples being applied is the least bit crooked, a line of brown glue will show. Paper companies want their sample booklets to be produced with the Chipping method so the glue is applied out to all four edges of the Chip. This prevents the Chips from being peeled off.

Chipping

Chipping

Chipping

When I have approached paper companies to do Chipping for them, the first question they always ask is, “Are you applying the glue to the carrier first or the sample piece first?” If my answer isn’t that we apply glue to the sample first, they won’t talk to me!

Chipping

Like the image above, you’ll notice that some Chips have 2 colours of samples that butt each other. If you rub your finger over the surface of the two coloured pieces that are “Butted” together they are perfectly smooth! Our company does both Chipping and Butting!

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.

Paste Binding

What is paste binding? It is a booklet that appears to be wire saddle stitched, but there are no wire stitches (staples). Rather than using wire stitches, the folded pages are held together with glue. Paste bound “booklets” are produced on a conventional “buckle” folding machine.

Paste Binding

In the late 1950’s, automatic saddle stitchers were introduced which cut the cost of producing saddle stitched books by about 90%! Prior to this saddle stitched books were hand fed on a wire stitching machine & then manually trimmed on a cutting machine. Prior to the 1950’s, “paste binding” was quite common. Most binderies did “paste binding”.  Paste binding has limitations compared to wire saddle stitching.

Features

  • Glue on every page at the spine
  • The spine lays flatter that wire saddle stitching

Paste Binding

Benefits

  • Sometimes much cheaper than saddle stitching
  • We can P.M.C. (HIGH DIE) shape paste bound booklet. When saddle stitched books are squeezed through the P.M.C. machine the stitches pop out!
  • When the booklet is being paste bound all in one pass, additional operations such a final soft fold and/or “clip” seals can be added on 1 or 2 or 3 sides all in one pass!

Paste Binding

Limitations

  • Narrower range of stocks
  • Depending on booklet size booklets can only be a maximum of 32 pages
  • Glued booklets cannot have a separate cover
  • Stocks cannot be mixed

Factors to consider

  • There are a number of physical limitations
  • We are one of the very few binderies can now do this process
  • Most suitable for long runs

Toronto Zoo – Event Introduction Tea Box Set

Event Introduction Tea Set

The Toronto Zoo wanted to celebrate the birth of the first Giant Panda cubs to be born in Canada. We produced this tea box set, which was sent to leading multicultural media outlets in advance of a name reveal event. The Toronto Zoo also wanted to spread the word about the new cubs, Jia Panpan and Jia Yueyue, and invite the public to see them.

Tea Box Set

There is a lot of symbolism in this box set. First, the colour scheme –black and white—reflect the Giana Panda’s colours.

Tea Box Set

The tea and teacup components recognize the Giant Panda’s origin and the birthplace of the mother Panda. Having two teacups represents the twin panda cubs.

Tea Box Set

As you can see in the above image, the two cups are placed to look like a Panda’s eyes. The foil stamped curved portion at the bottom is the mouth and the upper rounded corners are the ears.

Tea Box Set

The image above shows the letterpress printed introduction

We were very excited by the final product since this project conveyed the desired effect of warmth, tradition and celebration. We produced this entire project according to the designers’ direction. The public reception of the piece was excellent!

Features

  • Smooth
  • Lots of symbolism reflective of the panda cub exhibit
  • Only black and white

Benefits

  • Easy to access & reassemble after use
  • Unique
  • Functional

Factors to consider

  • The genius of this piece is in the design. Designers should always explore what materials are available to create the desired effect of the piece. There is an endless supply of unique materials we can work with!

Retail Packaging

What does retail packaging have to do with our bindery? Lots!

Retail Packaging

As you can see from the following pictures, we can do a wide range of retail packaging. Each job is completely custom, sometimes requiring several operations. All these products pictured require extensive hand assembly and with these products they all had to closed with either eyelets or rivets. Quantities range from hundreds to tens of thousands. Customers range from brokers to wholesalers, manufactures, distributors and stores.

Retail Packaging

Retail Packaging

Retail Packaging

Often, part of the jobs may require die-cutting, foil stamping, collating, and the final boxing or packaging of multiple pieces in appropriate boxes for shipping.

Retail Packaging

Retail Packaging

Features

  • Each job is completely unique
  • Each job requires both machine operations and extensive “hand-work”

Retail Packaging

Retail Packaging

Benefits

  • Multiple operations (as many as up to 12!) performed in our own plant
  • Very short production time because of our large capacity
  • We can also offer flat-wire stitching, side sewing, metal cornering, gluing, mounting, bar code labeling warehousing in our 72,500 square foot plant

Retail Packaging

Retail Packaging

Factors to Consider

  • For retail packaging projects, consider what components we are to supply, such as:
  • Clear vinyl
  • Heavy paper stocks for headers
  • Die-cutting
  • Foil stamping
  • Single ply/corrugate boxes for shipping

Wire-O Binding

Styles of Wire-O Binding

Our equipment can Wire-O books by the hundreds or hundreds of thousands. We don’t only bind regular Wire-O bind books, we can do a wide range of styles! With our 6 collators30 pockets6 automatic punching machines and 4 automatic Wire-O binders, we can:

  • Automatically cut, fold, collate, trim, punch and bind books from just two sheets thick up to 1 1/2” thick
  • Bind sizes from as small as 2” x 2” to as large as 28” x 30”
  • Bind oblong (landscape) or upright (portrait) formats
  • Bind a mix of sheet sizes and stocks, including plastic sheets
  • Add features like glued backs and thumb hold cut hangers
  • Bind using Wire-O in a total of 28 different colours

Cover Designs

  • Two Piece
  • Wrap-Around
  • Pasted Back
  • Reversible
  • Sleeve Inserted
  • Cased In
  • Easel
  • One Piece
  • Calendar

Wire-O Binding

The image above shows a shows 3 books in one binding. Wire-o binding is the best of 4 different styles to bind 2 or more books with one binding.

Wire-O Binding

The image above shows a cased-in Wire-O book

Wire-O Binding

The image above shows a 3-panel Wire-O book

Wire-O Binding

The image above shows a unique design that the designer wanted so it would stand out!

Wire-O Binding

The image above shows a one-piece cover with a split binding that allows better spacing for the spine title

Wire-O Binding

The image above shows an open cover punched only on the back cover. This design has Wire-O exposed on the back cover and allows for a full unpunched spine

Wire-O Binding

The image above shows Wire-O binding only on the front cover allowing for a full unpunched spine

What is miniature saddle stitching? 

Saddle Stitching

Miniature saddle stitching is simply a saddle stitched booklet which is probably smaller than any booklet you have ever seen! We do miniature saddle stitching . . . as small as 2” from the face to the spine and 1 3/4” from top to bottom! We bind the booklets more than one up; sometimes 2 up or maybe even 4 or 5 up, depending on the size. That’s one of the reasons we have incredible speed producing miniature saddle stitched book.

Saddle Stitching - SGFTeam.ca

Saddle Stitching - SGFTeam.ca

The booklets are produced in one machine operation which entails:

  1. Inserting sections
  2. Applying cover if there is one
  3. Stitching
  4. Single book blade trimming booklets on all three sides.

Saddle Stitching - SGFTeam.ca

IMG_4977-EDIT

These miniature booklets often require us to add further operations such as:

  • Miniature clip sealing
  • Final soft folding parallel to the spine
  • Tipping the booklets to printing carriers
  • Cellophane wrapping or shrink wrapping

Most miniature saddle stitched booklets are for the pharmaceutical or cosmetic industries. Needless to say, both of these industries are growing so we are seeing a bigger demand for miniature saddle stitched booklets! Now you know who to call when you have a need for extra small, miniature saddle stitching! Give Carol in Estimating a call at (416) 701-0111 ext. 311.

Saddle Stitching - SGFTeam.ca

Features

  • Very small and very light weight
  • Can hold a lot of information in a small piece

Saddle Stitching - SGFTeam.ca

Benefits

  • Fits into very, very small pharmaceutical and cosmetic boxes
  • Often more functional than a folded brochure
  • Perceived as more value added and upscale than a folded piece

Tag Stringing

What is tag stringing? Tag stringing is the completely automated process (thousands per hour), in which a machine performs the following functions in a single pass:

  1. Feeds the tag
  2. Punches a hole
  3. Pulls the string from a large cone of string and cuts it to a required length
  4. Inserts the string and ties a permanent knot
  5. Counts the tags into customer required quantities (20’s, 50’s, etc.)

Tag Stringing - Specialties Graphic Finishers

A term you might be asked by our estimator, is what is the length “hole to knot”? What this means is not how long the string is, but how long the tied string is from the knot to the tag hole. For instance, if the “hole to knot” is 3”, then if you were to cut the string and lay it out flat, it would measure 6”!

Tag Stringing - Specialties Graphic Finishers

The middle tag in the above image is a standard tag with a single panel, no die cut shaping or unusual size

Tag Stringing - Specialties Graphic Finishers

The image above shows a multi-panel tag

We have produced tags with up to 12 panels.  Some multi-paneled tags are often miniature saddle stitched booklets or “paste bound books”, (I’ll do a blog about “paste binding” in a few weeks) or miniature perfect bound books!

Tag Stringing - Specialties Graphic Finishers

The image above shows die cut tags

A large percentage of the tags we produce are die cut. As you can see in the image above, tags aren’t just limited to being round or square. They can be shapes like an orange, mango or pineapple!

Tag Stringing - Specialties Graphic Finishers

The image above shows a miniature tag

We are able to produce a wider range of miniature and oversized tags than our competition! If you have an extra small or extra-large tag in mind, give us a call!

Tag Stringing - Binding & Finishing SGFTEAM

The image above shows a star shaped tag, an example of a very difficult job to run

Features

  • Easy to attach to bottles or retail products
  • Numerous colours of string are available
  • Various lengths and textures of string
  • Cotton or elastic string makes each job unique

Benefits

  • String adds a very great amount of “value added” to the product as tags are very functional
  • Very low spoilage – often just .01%!
  • We have the largest trade “stringing capacity” in Canada