Design for Print - Binding Research

Binding is generally considered to be the process of fastening the sheets of a publication in the proper order and most often within a protective cover.
There are various methods of binding available that can be selected for the type of publication and/or for the type of handling it will receive. 

Perfect Binding
Perfect binding is one of the most commonly used binding methods. It is used for many types of publications.
Pages for a perfect bound publication are gathered, stacked, and placed in special equipment where the binding edge is covered with glue. A cover is then attached to the book to complete the process.
This method is most successful when the paper grain runs parallel with the spine of the book. Magazines and books may have the title and other information printed on the flat spine of the cover.
Perfect binding is one of the most automated of the binding methods. It can be divided into three main categories: hot adhesive, cold adhesive, and thermal binding.

Hot Adhesive Perfect Binding
Hot glue is the most widely used of the perfect binding adhesives. Books are usually 1/4” up to 2 1/4” thick depending on the thickness of the substrate. A major disadvantage with hot adhesive is that the book cannot lie flat when it is open. The binding will break if too much pressure is applied in attempting to make the book lie flat when it is open.


Cold Adhesive Perfect Binding
Cold glue is not used as often as hot glue because it is more expensive and requires more time to cure than hot glue, but it is stronger and more flexible.
When the cold adhesive is used in conjunction with a scored and hinged cover, the book is able to lie flat when it is open without cracking the binding. Books with perfect bindings made with cold adhesive range in thickness from 1/8” to 2 1/4”.

Thermal Binding
Thermal binding is similar to the hot adhesive method of perfect binding in that adhesive and heat are used to form the binding, but instead of hot glue, an adhesive strip is used.
Pages are fed into a machine where an adhesive strip attached to a wrap around cover is applied to the binding edge of the pages. Heat is applied so that the adhesive strip and cover are adhered to the pages.


Plastic Comb Binding
Plastic combs are another binding method that allow for the addition or removal of pages from a book. The system involves punching rectangular holes into pages, which are then slid over the fingers of the plastic comb.
A standard 11” sheet would have 19 holes punched into it. The plastic combs are durable and come in a variety of colors. Book titles or descriptions can be printed on the spine of the plastic comb so that the book can be identified when it is being stored.


Spiral
A spiral binding consists of a continuous wire, which is coiled through evenly spaced holes that have been punched into the pages of a book.
The spiral wire can be made of metal, plastic, or plastic coated metal. Plastic is available in a variety of colors, but the metal spiral has a limited color selection.
When the books are open, the pages lie flat. The pages can also be folded over completely, which makes spiral binding a good choice for training manuals, cookbooks, notebooks, and calendars

Double Loop Wire Binding
Double loop wire binding consists of a series of double wire loops from a continuous pre-formed wire, which are inserted into pages that have been punched with square or round holes.
The loops of the wire are held opened by a machine to allow the pages to be inserted over the loops. Once the loops are closed, extra pages cannot be added.
Double loop wire works best for books of one-inch thickness or less. Many technical manuals and cookbooks have this type of binding and they are very popular among architects

Double loop wire binding
is also known as “Wire-O-Binding”. Listed below are the types of wire available.
3:1 Wire: With this wire, the paper is punched 3 holes per inch, which is 32 holes per standard 11” sheet size. It is available in sizes ranging from 3/16” up to 9/16” in diameter. It has the best appearance of all double loop wire.
2:1 Wire: Pages are punched with 2 holes per inch or 21 holes per standard 11” sheet size. 2:1 wire is used for binding books that are too large for 3:1 wire and is available in sizes ranging from 5/8” to 1”. The wire is more durable and sturdy than 3:1 wire.
19 Loop: The pages are punched with 19 rectangular holes per standard 11” sheet size and the wire comes in diameters ranging from 1/4” to 1”. The wire is similar in appearance to 2:1 wire. 

Loose Leaf
Loose Leaf Binding is one of the simplest methods of binding. Cut pages are punched with holes to accommodate the rings or posts contained in the binder. An advantage to both ring or post binders is that pages can be added or removed easily.
The ring binder also has the advantage of allowing the pages to lie flat when the book is open, making it a good choice for technical or training manuals. An allowance for the inner margin (gutter) must be made to allow for the holes that are punched in the pages

Post Bind
Binds a group of loose leaf sheets using a screw and post inserted through the holes that are punched in the sheets

Saddle Stitching

A saddle-stitched publication has all sides of the pages trimmed except the spine. This is to make all the outside edges even. The "creep" causes the pages to protrude differently as the pages closest to the center will protrude more than the pages on the outside. If the elements are too close to the outer edge of the page, they may be trimmed off when we trim the pages to avoid a noticeable creep.

Saddle-stitching is ideal for those who opt for a self cover, are using a low paper weight, or have a small amount of pages to be bound. The process is to staple the pages in the center of the binding. It is most commonly used for catalogs and thin magazines. Saddle-stitch requires that pages be in multiples of 4.

Files for the pages and covers should be submitted as single pages. 

Perfect Binding

A perfect bound publication has all sides of the pages trimmed even at the spine. This called the "grind". The pages are "ground-off" to insure that the inside pages' edges are all even. 

Perfect binding glues all of the pages to the spine of the cover. The result is a completely even edge on the outside. This binding is optimal for those with many pages and a heavier paper weight cover. It is commonly used for higher volume magazines and luxury catalogs.

PUR Perfect Binding

PUR (polyurethane reactive) binding follows the exact same process as perfect binding except we change the glue from Perfect Binding Adhesive to PUR Adhesive by exchanging the glue pots. PUR glue reacts with the moisture content in the paper and the chemical reaction creates a much stronger bind than the conventional glue.

PUR is the strongest, most flexible binding adhesive available. The thin, tough, and flexible consistency of PUR enables the magazine to open easily and can lay open flat. It's the optimal choice for projects that will see frequent use and demand durability.

Spiral Binding

A spiral binding consists of a continuous wire, which is coiled through evenly spaced holes that have been punched into the pages of a book. The spiral wire can be made of metal, plastic, or plastic coated metal. When the books are open, the pages lie flat. The pages can also be folded over completely, which makes spiral binding a good choice for training manuals, cookbooks, notebooks, and calendars.

Print Coatings

Coatings are applied to the protect the printed pages from moisture, extreme temperatures, scuffs, scratches, and frequent handling. They are also used to draw the eye to a particular element on the page. We offer four types of print coatings: overprint varnish, aqueous coating, lamination, and UV coating. All four are available in matte, dull, satin, and glossy. Please note that coatings appear differently on uncoated paper versus coated paper. If you plan on writing or rubber stamping on your publication, we suggest not using any coating as it will limit your ability to write on the paper.

Laminate

Lamination comes in two types, film-based and liquid-based. Either a clear plastic film is laid down over the sheet of paper or a clear liquid is spread over the sheet and dries (or cures) like a varnish. Liquid lamination protects paper from water but is slow to apply and is costly. However, it provides a strong, washable surface. 
Film lamination features a high gloss finish with a very smooth, tough finish. This durable plastic film has advantages over liquid coating at a slightly higher cost. Film lamination will not yellow with age, flake off, and is scratch resistant. In addition, the ink is protected from cracking and provides an odorless/wipeable surface.

UV Coating

Ultra-violet coating is the glossiest coating available and is less commonly available in dull and matte. UV coating is a clear liquid that is spread over the paper like ink. It can be used as a spot covering to accent a particular image or logo on the page or as an full page (flood) coating. UV coating gives more protection and shine than varnish or aqueous coating. UV coating is unsaturated polyester or polyacrylate based and when exposed to ultraviolet light, dries instantly. UV coating offers excellent rub protection.

UV coating is applied as a separate finishing operation as either a flood coating or (applied by screen printing) as a spot coating. Keep in mind that this thick coating may crack when scored or folded.

Aqueous Coatings

Aqueous coatings are water-based and are applied by an inking unit of the press or in a special coater. Aqueous has the advantage over varnish because it dries immediately and has glossy characteristic that falls between varnish and UV coating. Since aqueous can be applied over wet ink, can seal the printed sheet, and can dry immediately, it has the practical advantage of reducing handling time for trimming and other post-press operations.

The disadvantage of aqueous is that since it is water-based it can cause paper to curl, particularly on thinner paper weights. Additionally, certain pigments may bleed with aqueous. Aqueous coating is only recommended for coated sheets as it will be absorbed by uncoated paper stocks. 

Specialty Finishing

Foil Stamping

When a print project needs an elegant, non-tarnishing metallic finish to be applied to paper, it’s easily done using a process referred to as foil stamping or hot stamping. A wide selection of foil colors, finishes, and effects are available such as: gold, silver, colored metallics, marble, leather, wood, snakeskin, and pearl finishes; in geometric multi-dimensional patterns.

Embossing

Embossing is a process that applies pressure to the backside of paper to alter the surface, giving it a three dimensional or raised effect. It is often used in combination with foil stamping. The procedure involves the use of two dies, one fitting into the other so that the raised die forces the paper into the recessed die to create the embossed impression. The die maker engraves the desired image into several metal plates, which are the embossing dies for the embossing press to use. Generally, embossing is the process most used to attract attention or to convey a high quality textural contrast. Also available is debossing, the opposite effect of embossing.

Die Cutting

Die cutting is the process of cutting shapes from sheets of plastic by pressing a shaped knife edge into layers of sheeting. The dies are often called steel rule dies and pressure is applied by a hydraulic or mechanical presses. The main method of die cutting involves the use of metal dies to give paper specific cut out shapes or designs that cannot be accomplished with a straight cut on a guillotine cutter.

Pantone Color

Pantone, or PMS, color is any color that is used on a document that is not a process color. These are often used to create special effects or to meet a company's branding standards with a specific color. Specialty inks can be used as a spot color to provide even greater emphasis to a print. These inks can range from fluorescent, fade resistant, opaque, and metallic.