Book Bindery Primer
Binding is the process required for turning printed sheets into books. NPC has some in-line (finishing units attached to our presses), as well as dedicated binding and finishing equipment.
Assembling individual sheets for binding is called collating. Assembling signatures, one on top of the other in proper sequence, is called gathering; assembling signatures, one inside another in sequence, is referred to as inserting.
Printed press sheets are delivered to the bindery as a stack of single sheets from a sheetfed press or as folded signatures from a web press. After printed sheets have been folded, they must be assembled in proper sequence before binding.
The work required for turning these printed sheets or signatures into books, catalogs, booklets, manuals and directories is called binding. Some manufacturers have in-line binding or finishing units attached to their presses. Some have stand-alone, dedicated equipment. NPC has the capabilities of both.
Here's a rundown of NPC's book bindery options along with typical page counts suited for each method.
| Bind Style | Page Count |
|---|---|
| Perfect Bind | 96 pages and up |
| Saddle-Stitch | 8-96 pages |
| Side-Stitch | 8-160 pages |
| Paste-on-Fold | 8, 16, 32, and 48 pages |
| Loose-Leaf | 8 pages and up |
Perfect Binding
A book that has perfect binding, or adhesive binding, has a soft cover with a rectangular backbone. Glue or another adhesive is the only binding material used in perfect binding.
Adhesive binding produces a book that opens easily and lies reasonably flat due to a hinge score, an impression or indent mark made in the cover that makes folding away from the spine easier.
The binding edge of the product is usually trimmed, milled to 3/16 inch, and roughened to make the sheets more receptive to the adhesive. Once the adhesive is applied, the cover is pressed against the book's spine and held in place by the glue.
A book that has a different cover stock than the inside pages, whether it is simply a different weight or a completely different stock, is considered a separate cover. Perfect-bound books require a separate cover.
Perfect binding offers a number of advantages. The backbone of the wraparound cover can be printed with the name of the book for easy reference when stacked on a shelf. It is typically used for larger page counts and for books that require a more durable binding style. Perfect-bound books typically have a longer shelf life.
Typical NPC perfect bound-books meet the following specifications. However, check with your representative if your project falls outside of these ranges:
| Book size in inches | Number of Pages |
|---|---|
| 8 x 10 - 8 1/2 x 11 | 96 pages and up |
| 5 x 8 - 5 1/2 x 8 | |
| Text | Cover |
| 1-, 2-, or 3-color printing | Spot or Color Processed |
Once bound, books may also be drilled and/or shrink-wrapped.
Catalogs, manuals, booklets and directories are products that frequently use perfect binding.
Saddle-Stitching
Saddle-stitch binding, probably the most popular form of joining signatures, is widely used in manufacturing thin directories, manuals, booklets, brochures and programs for public events.
Two types of covers can be used in this binding style. Like the perfect-bound book, saddle-stitched books can have a separate cover. However, they offer the option of a self-cover. The self-cover is a book with both the cover and text the same paper weight and stock.
The saddle process consists of collating signatures, or parts of a book, and binding them with or without a cover. Collation is an automated process of ordering the parts of a book in the proper pagination or page number sequence. The saddle-stitch equipment has sophisticated electronics that verifies that every signature is gathered and sequenced correctly. In this process, signatures are aligned on top of an angled metal surface called a saddle, with the folds in the signatures centered on top of the saddle. Staples are then driven through the stack of papers aligned with the fold to bind the signatures together.
An automated binding machine, used to staple the signatures, uses a conveyor chain and a stitching head. Like a high-speed mechanical needle and thread, this method uses rolls of thin wire that are cut, bent and inserted as needed. When staples are created from a roll of wire, the process is called stitching instead of stapling.
There are usually two stitches or wires centered an equal distance from either edge of the finished piece. On oversized books or books with high page counts, three or more staples can be used. The book cover and body are stitched at the same time, even if the text and cover are printed on different stocks.
NPC typically manufactures saddle-stitched books within the following specification ranges:
| Book size in inches | Number of Pages |
|---|---|
| 8 x 10 - 8 1/2 x 11 | 8-96 pages |
| 5 x 8 - 5 1/2 x 8 | |
| Text | Cover |
| 1-, 2-, or 3-color printing | Spot or Color Processed |
Trimming the top, bottom and front edge of the printed pieces usually follows saddle-stitching. Once a saddle-stitch book is manufactured, it can also be drilled and/or shrink-wrapped.
Side-Stitching
Side-stitching involves fastening wire stitches through the side of a book, parallel to its binding edge. This binding process is used primarily for thick publications. It is less durable than a perfect-bound book and often is drilled so it can be placed in a ring binder. This binding style provides a shelf life similar to that of paste-on-fold or saddle-stitched products. The military uses this type of binding for a number of their training manuals.
Side-stitched books can have either a separate cover or a self-cover.
NPC produces side-stitched books to the following specifications:
| Book size in inches | Number of Pages |
|---|---|
| 8 x 10 - 8 1/2 x 11 | 8-160 pages |
| 5 x 8 - 5 1/2 x 8 1/2 | |
| Text | Cover |
| 1- and 2-color printing | Spot or Color Processed |
After the books have been side-stitched, they are trimmed on the top, bottom and opening edge. They can then be drilled and/or shrink-wrapped.
Paste-on-Fold
The paste-on-fold binding method is more cost effective to produce than a saddle-stitch or perfect-bound book. Products that have a short shelf life or will be updated frequently may be bound using this style to reduce cost. Examples of paste-on-fold products are college course schedules and seminar catalogs.
To manufacture a paste-on-fold book, as the booklet is being printed, glue is applied to the spine of the signature, and then folded and trimmed in-line. The finished product is a book similar to a TV directory often included in a Sunday newspaper. With a paste-on-fold book, the cover must be the same paper stock as the inside text pages - a self-cover.
At NPC, paste-on-fold books can be manufactured to the following specifications:
| Book size in inches | Number of Pages |
|---|---|
| 8 x 10 - 8 1/2 x 11 | 8, 16, 32 or 48 pages |
| Text | Cover |
| 1-color printing | 1-color printing |
Paste-on-fold products can be drilled and/or shrink-wrapped.
Loose-leaf
A loose-leaf book technically has no binding, so it can be used in a number of ways. This binding method allows readers to alter the publication by adding and deleting pages at will. Loose-leaf binding is a perfect solution when documents require continuous updating.
Books with page counts lower than 160 are manufactured in-line. Larger books are collated in proper order and have glue applied to the edges. They are then trimmed on all four sides and sent to the auto drill. A loose-leaf product can have a separate cover or a self-cover.
In setting up a document to be loose-leaf bound, remember to allow an adequate margin for drilling if it is required.
Loose-leaf products can be manufactured to the following specifications:
At NPC, paste-on-fold books can be manufactured to the following specifications:
| Book size in inches | Number of Pages |
|---|---|
| 8 x 10 - 8 1/2 x 11 | 8 pages and up |
| Text | Cover |
| 1- and 2-color printing | Spot or Color Processed |
Loose-leaf products can be shrink-wrapped.
