Forms Bindery Primer
Cut-Sheet Forms
Once the ink hits the paper for any type of form manufactured, the printed sheets are stacked on boards and then transferred to a flatbed, a machine that cuts large stacks of printed sheets to their exact trim size. Trim sizes for forms offered by NPC include (inches):
- 4 1/4 x 5 1/2
- 3 2/3 x 8 1/2
- 5 1/2 x 8 1/2
- 8 1/2 x 11
- 8 1/2 x 14
- 17 x 11
- 25 1/2 x 11
- 8 1/2 x 33
These flat printed sheets can leave the plant as either flat forms or be transferred to a variety of bindery operations.
Bindery styles offered for forms include the following:
- Folding
- Perforation
- Padding
- Drilling
- Shrink-Wrapping
Folding
Folding is the process that doubles a sheet of paper so that one part lies on top of another. A folder is a piece of bindery equipment that can fold, slit and perforate paper. NPC uses both stand-alone folders for forms and presses equipped with folders.
Folding stresses the paper fibers. To create a smooth, straight fold, heavy papers like cover stocks need to be scored before they are folded. Scoring presses a channel into a sheet of paper to allow it to fold more easily. There are two types of scores: Wet scores for regular paper and a roto crease for index-type stock.
Scoring and pressing the paper fibers together creates an embossed channel that does two things: Acts as a guide for easier folding and creates a hinge that keeps the fiber stretch short. The score should run parallel to the paper grain; the thicker the paper, the wider the score should be. Paper should be folded with the scored side on the outside.
There are a number of folds that can be applied to any printed piece. Here are the common folds used at NPC:
Accordion or Z Fold:
Wrap-Around, C-Fold or Letter Fold:
Parallel or Single:
Double Parallel:
Accordion folds are used in the manufacturing of road maps and brochures. Wrap-around folds are widely used in the folding of letters. Parallel folds are used to fold a piece of paper in half.
Form products can then be boxed, or banded and boxed. Form products may also be drilled and/or shrink-wrapped.
Perforation
Perforations are small cuts in paper that make an area easily separated by tearing or to assist in folding a signature. NPC can produce traditional perforations as well as micro-perfs (slits are smaller and closer together). Perfs are metal strips with sharp areas that cut through the paper to create a perforation.
Padding
Padding is a bindery process that applies a hot-melt adhesive to one edge of a stack of clamped, loose sheets. The finished product resembles a tablet.
The printed sheets travel from a flatbed, a machine that cuts large stacks of sheets to their exact trim size, to a padder. The padder applies adhesive to one edge. The materials are then stacked on a board or skid.
Choosing to have your products bound in a padded bindery style keeps the forms together, but makes them easy to pull off individually. A good example of a padded form is a doctor's prescription pad.
Padding can be applied to forms for the following trim sizes (inches):
- 4 1/4 x 5 1/2
- 3 2/3 x 8 1/2
- 5 1/2 x 8 1/2
- 8 1/2 x 11
- 8 1/2 x 14
Padded products then can be drilled or shrink-wrapped.
