OVERSIZED PERFECT BINDING

In this video, I show 3 different oversized perfect bound books. I’ve done a few videos in the past about our oversized perfect binding capabilities, but we’re pushing the size limit again! We can now perfect bind books that measure 20” from spine to face or 20” head to foot. We can also Smythe thread sew books that are 20” wide from face-to-spine.

OVERSIZED PERFECT BINDING

In this video, I show 3 different oversized perfect bound books. I’ve done a few videos in the past about our oversized perfect binding capabilities, but we’re pushing the size limit again! We can now perfect bind books that measure 20” from spine to face or 20” head to foot. We can also Smythe thread sew books that are 20” wide from face-to-spine.

In this video, I show 3 different oversized perfect bound books. I’ve done a few videos in the past about our oversized perfect binding capabilities, but we’re pushing the size limit again! We can now perfect bind books that measure 20” from spine to face or 20” head to foot. We can also Smythe thread sew books that are 20” wide from face-to-spine.

In addition to producing oversized perfect bound books, we can add features like folded flaps on the front and/or back covers (flush or short), which you can see in the image below.

OVERSIZED PERFECT BINDING

Another feature we can add to a 20” wide book is reverse 4pg foldouts, which when opened flat, can make the spread 80” side to side! You can see how amazing this looks in the images below.

 OVERSIZED PERFECT BINDING

If oversized perfect bound book is 20” wide face-to-spine, we can make it up to 18” head-to-foot. If an oversized perfect bound book has a 20” spine, we can make up to a 15” face-to-spine.

OVERSIZED PERFECT BINDING

We can also add foldouts on the top and bottom, which can be triple the height of the book (If book is 15” head to foot, the foldouts could be 45” top-to-bottom)!

 

DIECUT “TWIST” BOX

DIECUT “TWIST” BOX

DIECUT “TWIST” BOX

Did you know we make collapsible boxes? We are known more for our casewrapped/lithowrapped boxes, but we also produce diecut and glued boxes. The box featured in this video was printed on a standard 28” x 40” 10pt coated stock. We then diecut and diecreased the sheets multiple-up on one of our 4 40” Bobst/Brausse diecutters. If we needed to diecut larger sheet sizes, we can diecut sheets up to 30” x 56” on our Bobst! We can produce smaller runs of about 2,000 up to huge runs of 250,000.

DIECUT “TWIST” BOX

The sheets for this job then passed through one of our 5 box gluers, each of which can run this job at thousands per hour. The box gluers added a line of hotmelt glue and then a simple double fold and the box is ready! This piece was shipped flat to the client for the insertion of the final product. The customer simply squeezes the box, it pops open easy and then “locks” shut by twisting the ends.

DIECUT “TWIST” BOX

Embroidered Covers

Embroidered Covers

Are you looking for a new way to make your hardback/casebound book stand out? Look at what a beautifully embroidered covers can do for a book! We can produce embroidered hardback/casebound books.

Embroidered Covers

While we do not do embroidery in-house, we know what fabrics and materials work for both the bookbinding process as well as for various embroidery styles. Embroidery designs can vary in the number of levels and the amount of detail. For instance, the company that embroidered the image below uses different technology than for the picture below.

Embroidered Covers

 

Each embroidery company has different kinds of technologies. The range in technology can produce designs that can be highly detailed or very simple and with various levels (height and layering of stitches). We can produce runs of casebound/hardback books in runs from a hundred to several thousand. We’re noticing more frequent requests and use of embroidered covers, largely because the companies that do embroidery are increasingly sophisticated, automated and efficient. If your client is wanting a new idea for their book project, think about adding an Embroidered Cover!

Environmentally Friendly Book

Environmentally Friendly Book

The book featured in this week’s email was a corporate sustainability report we produced for a substantial company. Because of the focus of the report, the client did not want to use hot-melt glue that is used perfect binding because hot-melt glue is not easily recycled. Saddle stitching, another common book binding method, was not possible because the project required a printed, square spine. One option considered was to full surface glue the last page of a saddle stitched book to the inside back cover of a double-creased cover. The client decided against saddle stitching, though, because of the metal stitches required.

Ultimately, the product resulted in producing the booklet in two parts. First, we offline double-creased an outside cover (see image below).

Environmentally Friendly Book

Next, we used thread to centre/saddle sew the actual booklet and then hand glued the booklet into the inside back cover (see image below).

Environmentally Friendly Book

Environmentally Friendly Book

Because this product required offline creasing and hand gluing the cost of producing this product was substantially more expensive compared to normal perfect binding was 30 times more. While, this Environmentally Friendly Book was costly, it mirrored the focus and content of a corporate sustainability report. This is just one example of how we are continually generating innovations and finding new ways to combine processes.

Double Thick Covers

You’ve probably seen a die-cut “candy book” similar to this one. What’s interesting about this piece is only seen when you open the front cover.

If you look carefully, you can see that the cover of the “candy books” shown in the above two images is double thick and folded back on itself and surfaced glued. Essentially, the front cover is a 4-page folded back and glued on itself. The reason for this is so there can be copy/design on the inside of the cover without requiring printing on both sides of the stock! This saves printers a lot of time and money! We can produce a product like this at high speeds on one of our five fully automatic box gluers.

This type of “candy book” is unique because:

  1. The double thick cover/flap allows for more advertising space, while saving on printing costs. Talk to us about this design option when budget is a concern!
  2.  After picking up this “candy book,” the consumer will immediately notice the sturdy double thick glued flap.
  3. Like all unusual pieces, this product gets interest and has many applications!

3-Panel Pullout

3-Panel Pullout

You’ve probably seen a 1 or 2-panel pullout but have you ever seen a telescoping 3 or 4-panel pullout? If your customer needs a 3 or 4-panel pullout, we’re the bindery to call! We can do a single panel pullout completely automatically. Any additional panels are inserted manually. Pullout marketing pieces with 1, 2, 3 or 4-panels can be used for direct mail campaigns (if they have a wafer/clip seal applied to the open edge), inserted into magazines or packaged with a product.

3-Panel Pullout

The image above shows the carrier of a telescoping 2-panel pullout.

3-Panel Pullout

The image above shows how the 2 panels telescope into the carrier.

 

Step Cutting

We are able to “step-cut”, as shown in pictures #1 and #2.  We step cut books that are already bound such as perfect bound books, saddle stitched or hard back books!  Pictures #1 and #2 illustrates “step-cut” books.  The “steps” can be of various widths and lengths.  Different from step-cutting is “face-cutting” illustrated in pictures #2 and #3.  Pages get progressively shorter towards the spine of the book resulting in “steps”.  For instance the first step might be 20 pages, the next step 42 pages, the next step 16 pages etc.  Pictures #5 and #6 illustrate “corner cutting”.  The “steps”, progress from the corner of the book.  In this instance the steps were on the lower corner of the English side and when you flipped the book over the “steps” were on the opposite corner of a different language!

 

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.  We only do difficult or unusual tipping jobs!  We have the machinery to do:

  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 12page saddles 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, gatefolds, 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)

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 with ⅛” 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

For tipping that is unusual please call us…we can help!

Tipping

Tipping

Tipping

Tipping

Tipping

Tipping

Tipping

Tipping

Tag Stringing

We do tag stringing…lots of it!  As you can see from the pictures, we string round tags, undersized tags, booklet tags, oversized tags, extra long string loops.  Aside from the average sized tags, we can also automatically string tags that have been “riveted” with metal eyelets.  You can see from these pictures that we can supply a very wide range of string colours.  We can also supply string in two or three colours such as blue and red or white and black.  We also do “tag looping”.  This is an automatic process, it is similar to regular tag stringing in that the machine automatically inline punches that hole, but is different in that the string is “tied” at the hole leaving strands of equal length at either side of the hole.  This process allows someone to “tie” the string around a pipe, or handle etc.  In addition to tag stringing and tag looping we can also automatically “wire” tags.  As in the two previous processes a machine automatically punches a hole inline, then inserts, cuts and twists the wire into a “loop”.

TAG STRINGING

TAG STRINGING

TAG STRINGING

TAG STRINGING

Glueless Tipping

This product is unusual.  I am not sure what to call it.  To call it “glueless tipping”, would be a contradiction of meaning, because “tipping” by definitions has glue in it!  Whatever it should be called, it is an unusual product.  This process is almost impossible to produce because machines that do tipping requires gluing a card or something similar to a “carrier”.  At high speeds, if the card is not glued, it will fly in all directions!  In this situation, the card which is “shot” out of a high speed “feeder”, hits an air blast that adequately registers the card before the carrier enters the double plough fold folding station.

The benefit of this type of job is that upon opening the piece, the card falls into the hand of the customer.  No peeling the card off…no sticky glue…more environmentally friendly etc.…

For ideas that help sell products … if you need something different … please call us … we can help!

Glueless Tipping

Glueless Tipping