Unusual Binding Styles

The feature of this week’s email are a few binding methods that are not as common as perfect binding and saddle stitching. As a premier full-service bindery, we offer a range of unique binding options to elevate your customer’s book binding job.

ELASTIC BOOK BINDING

Unusual Binding Styles

Elastic book binding is highly unusual and, therefore, memorable! Books can be various sizes and thicknesses. The special elastics we source come in different widths and colours. In some situations, the elastic can be printed, for a fully custom look.

JAPANESE BOOK BINDING

Unusual Binding Styles

Japanese binding is a glue free book binding option, which used several threads to create loops around the spine. Almost any thickness of book can be bound using this method.

DOME BOOK BINDING

Book Binding

Dome binding is a good binding method for thin books up to 3/8” thick. Books are perfect bound and can then have 2 or more dome rivets applied along the spine.

SIDE SEW BOOK BINDING

Unusual Binding Styles

Side sew book binding is one of my favourite binding methods. Because the thread is visible from the front and back, this binding method is perfect for making a statement. There are numerous colours of thread to pick from. It’s perfect for thin books up to 1/4” thick. Numerous colours of thread. As mentioned in the video, sometimes two lines of two different colours of thread is very effective.

BOX STITCH BOOK BINDING

Box stitching is done as a secondary and purely aesthetic method of book binding. Perfect bound books up to ¼” thick can have copper or silver box stitches applied.

EYELET AND GROMMET BOOK BINDING

We have a huge capacity for eyelet and grommet binding. Our 18 riveting / eyeletting machines are always busy as demand for value-added features continues to grow. As you can see in the sample board, there is a huge range of sizes and colours. Whether your book project is thin or thick, we have a binding option for you!

TIPPING EXTRA PAGES

 

TIPPING EXTRA PAGES

Tipping Extra Pages

The feature of this week’s email is tipping an extra page into saddle stitched books or folded mailers that cannot be stitched. You might be asking, “Is this a necessary service?” The quick answer is, “yes!” and I’ll explain why. Saddle stitched books need signatures in multiples of 4 (8pg, 12pg, 16pg, etc.). A client, for various reasons, might have a 10pg or 14pg booklet they want saddle stitched and a fold-out isn’t an option or is too expensive. Or a client has a mailer that needs to be in a booklet style but can’t have added stitches. What do you do? Give us a call!

*Disclaimer: We did not produce this specific piece, which was a web press run of 5.8 million. We are a great option for your client, if they have a mailer like this and the run is too small (under 50,000) for a web press.*

The folded mailer I’m showing has four processes, which can all be done in-line. First, we tip on a single sheet (in this case, pages 3 & 4); fold and glue a pocket; apply a strip of remoistenable glue; and then apply glue to the spine and make the final fold.

TIPPING EXTRA PAGES

TIPPING EXTRA PAGES

Does your client have an extra 2 pages that will complicate a saddle stitching job? Do they need an extra page tipped onto a folded  mailer? Give us a call and we can inline tip the extra page inside!

“A picture is worth a thousand words; a sample is worth a thousand pictures … need a sample? Just ask!”

Giant High-Speed Tipping

This is an example of Giant High-Speed Tipping! Our specialty lies in doing Difficult and Unusual Tipping jobs! This particular job is a 44” wide sheet that we folded automatically and  then tipped on a card.

Giant High-Speed Tipping

We have the machinery and expertise to tackle a wide range of unusual High-Speed Tipping jobs like:

  1. Tipping 2 or 3 pieces side-by-side onto a single side of a carrier
  2. Tipping onto both sides of a carrier
  3. Tipping Product Samples that are filled with liquid
  4. Tipping products automatically on the inside pages of saddle stitched books
  5. Tipping jagged or irregularly shaped products automatically
  6. Tipping onto sheets as large as 44” x 80”, and then folding and gluing the sheet

Giant High-Speed Tipping

Tipping onto a sheet 28” x 40” up to 44” x 80” can be a great option for automatically tipping a card onto a page inside Perfect Bound or Case Bound books. For example, we would tip a card onto an inside page of a 16-page signature, which could then be fed into a perfect binder at normal speed. This is a tremendous cost savings!

For Giant High Speed Tipping jobs, please call us at (416) 701-0111 ext. 311 or email at quotes@sgfteam.ca. We can help!

Folded PMC / High Die Cut Circles

Folding

Look at how many folds this Circle has – We did all 6 folds automatically!

How do other binderies fold a die cut circle? Most would start with a die cut circle that has one corner that’s perforated. The sheet would be folded like any other, (but limited to one or two folds) and then the perforated section would be hand stripped to reveal the final circle. This method has 3 problems:

1) This method is time consuming and costly;

2) Most are limited to doing only two folds; and

3) The final circle has the leftover perforations marks!

How does our bindery make a Folded Circle without any perf marks? We are always innovating, and Folding Circles is something we can do completely automatically and without any perforations.

First, we cut sheets with our PMC / High Die Cutting machines to cut ultra smooth Circles. Then we fold the Circles on an extremely rare folding machine that has no register table or side guides. We simply place a 4-inch pile of PMC / High Die Cut circles into the hopper and the folding machine catches the bottom circle and brings it right onto the folding plates. From there, we do 6 folds and produce a smooth Folded Circle that has a clip seal / wafer seal.

These are the benefits of our method:

1.  PMC / High Die Cutting is a much cheaper way to cut circles than die cutting

2.  PMC / High Die Cutting produces smooth edged circles without perf marks

3.  We can do up to 6 folds all automatically and add a clip seal / wafer seal

Notice how many folds this piece has! If you need PMC / High Die Cut Circles folded once, twice or up to six times, please make us your first call!

 

Cross Fold with Glueless Insert

The challenge of a Cross Fold piece like this one isn’t the die cutting or folding. Gluing the inserts onto the Cross Folder is the typical way of doing this job. But, as you can see in the video and the image below, the insert on the centre panel is not attached by glue! A piece like this is produced automatically and in just one pass, which reduces spoilage and the cost of the job.

Cross Fold with Glueless Insert

Cross Fold with Glueless Insert

Cross Fold with Glueless Insert

Cross Fold with Glueless Insert

How can we produce a job like this automatically? As we frequently do, we have a trick up our sleeve! We use a tipping machine to “tip” the sheet on the centre panel with a drop of water. The drop of water temporarily holds the insert in place as the carrier travels through the machine. This piece has one wafer/clip seal, but we can apply 1, 2 or 3 wafer/clip seals inline.

If you need innovative, creative solutions to your job challenges, please call us – we can help!

 

34” Long Buckle Fold

Do you have a Buckle Folding job that’s larger than 30”? All but a few Buckle Folders are 30” or smaller, which limits printers that print 28” x 40” sheets. We have 34” Buckle Folders, so give us a call if you’re having difficulty finding a finisher!

Buckle Fold

Buckle Fold

Long Buckle Fold

We frequently do jobs that are guillotined to 22” x 34”, requiring us to fold it to 11” x 34” and then parallel accordion or roll or double gate fold on the right angle to final size of 8.5” x 11”. For jobs that require folding larger than 30”, we can be of service!

TRIANGLE FOLD

One style of folding you don’t see very often is Triangle Folding. This style of folding is a great option because it’s distinctive, memorable and just plain different! We can do a Triangle Fold on sizes up to 20” x 20” on 50lb to 100lb offset.

Triangle Fold

Triangle Fold

A Triangle Fold can have multiple panels. For instance, a piece that measures 10” x 40” could be accordion folded down to 10” x 10” and then right angle folded. Then, for the final Triangle Fold, we “bump and turn” the sheets and then, depending on the stock and number of panels, we plow or knife fold.

Triangle Folding

Triangle Folding

If your customer is looking for a new, interesting way to fold a job, give us a call!

Map Folding

There are only a few binderies in North America that can efficiently fold huge
quantities of maps on sheets as large as 44” x 80”.

The above images show a plastic map with a number of accordion folds.
We can do up to 24 accordion folds on our machines.

The two images below show common road maps that we fold.

Map Folding

The two images below have 5 accordion folds and the right angle folded.

The two images below show a smaller map

Map Folding

Map Folding

Large Sheet Accordion Folding

Accordion Folding is just one of the many services our bindery offers. We can produce 24 accordion folds in one pass . . . on sheets as large as 44” wide! If you’re trying to get a job folded that is unusual or tough for other binderies, please give us a call.

Large Sheet Accordion Folding

We also do extra-small Accordion Folding jobs. Our machines can Accordion Fold pieces as small as 3/4” wide!

Miniature/Pharmaceutical Folding

We regularly do Miniature/Pharmaceutical Folding on our 7 miniature folding machines. We can make folds as small as 5/8″ and can fold stock as light as 30lb! We can knife fold/fugitive glue shut and, for some jobs, we can add a wafer/clip seal. If your customer is calling about Miniature/Pharmaceutical Folding on light stock, give us a call!

Miniature Folding - Pharmaceutical Folding

Miniature Folding - Pharmaceutical Folding

Miniature Folding - Pharmaceutical Folding

Miniature Folding - Pharmaceutical Folding

Miniature Folding - Pharmaceutical Folding