Finishing Processes
While bindery and finishing are usually the last phases of a printed job, it is important to identify your requirements up front when planning the job so all will run smoothly. Hopefully this page will be helpful in making decisions on some of the finishing services that we offer.
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Binding options...
Saddle stitching derives from the device called a saddle on which the folded signatures are placed before being stitched from a continuous spool of wire - with the saddle in the fold. We also offer loop stitching for ring binder brochures.
Advantages: Booklets will open flat and is the most economical form of binding.
Disadvantages: Limited maximum number of pages up to 60 depending on paper weight. "Creep out" of inner pages occurs as more pages are added on top and inner pages are pushed outward on the fore edge by the thickness of the book.
An ideal alternative to punching holes for brochures for ring binders.
Perfect binding is a method of soft cover bookbinding using a hot melt EVA glue (Ethylene Vinyl Acetate) which sets quickly.
Advantages: Sets quickly and books can be trimmed immediately. Relatively inexpensive form of binding.
Disadvantages: Spine can break if forced flat and pages will come away.
Ideally suited to weights up to 150gsm, heavier weights should be PUR bound or Thread sewn.
Similar to Perfect binding PUR Stands for PolyUrethane Reactive binding. It is used on jobs that require greater binding strength.
Advantages: Stronger bind than conventional hot melt glues. Bound books open flatter than standard hot melt.
Disadvantages: It takes at least 24 hours to cure and text pages should be no more than 170gsm in weight. It costs more than standard hot melt glue.
Thread Sewing is where folios or sections, usually in 16 pages are threaded together to form a book block.
Advantages: Books last longer and open flat.
Disadvantages: Costly.
Case Binding (Hard back books)
A book bound with a stiff 2mm cover that is covered by fabric or other material that can include a printed sheet.
Advantages: Books last longer and give a professional finish to your publication.
Disadvantages: Expensive and time consuming.
Plastic spiral binding (also known as or plastic coil binding) is available in up to 45 coil colours in any length and a range of diameters between 6mm and 33mm.
Plastic spiral binding is a single piece of plastic wound through holes punched at 4:1 (4 per inch). The end is bent over and locked in place. Spiral binding is a practical and durable way to bind 'heavy use' items such as road atlases, educational publications and children's books.
Advantages: All of the document's pages lie flat when opened and can turn easily through 360 degrees, ideal for manuals.
Disadvantages: Expensive unit cost and more time consuming than wire binding.
Binds a document firmly in place by a double-loop metal wire inserted through holes punched in the binding edge.
Advantages: All of the document's pages lie flat when opened and can turn easily through 360 degrees, ideal for manuals.
Disadvantages: Expensive unit cost, the wire can look unsightly.
Booklets are stab sewn and knot tied, there is a good selection of thread colours to choose from.
Advantages: Much more appealing than stapling.
Disadvantage: Restriction to one 16 page section and costly to do.
Booklets are singer sewn about 10mm in from the spine, there is a good selection of thread colours to choose from.
Advantages: Much more appealing than stapling.
Disadvantage: Restriction to 4.5mm maximum book thickness and uncoated papers, it is a slow process so allow extra time.
Our Bourg collator we use for collating NCR sets and collating inserts for pocket folders.
Advantages: Speeds up the collating finishing process.
Disadvantages: Not ideal for heavy stocks.
Die cutting is where a cutting forme or die is created by forming metal blades to the shape required and set into a timber block.
Advantages: Eye catching designs can lift a product. Required for pocket folders, envelope production, complex perforations, heavy stock finishing.
Disadvantages: Formes can be costly in the making for intricate shapes or the need to duplicate for large runs. Very intricate shapes should be avoided and are restricted to how far the metal blade is required be formed before breaking.
Duplexing is gluing sheets together to add extra thickness.
Advantages: Visually better to use two different coloured boards or sandwiching a white between two coloured boards.
Disadvantages: Costly and time consuming.
Embossing is a process by which blocks (dies) are used to stamp a relief image and Debossed is a process by which blocks (dies) are used to stamp a sunken image. Embossing requires both male and female magnesium blocks while debossing requires just a male block.
Advantages: Gives a lift to the printed surface and is ideally suited to heavier uncoated stocks. We find embossing works best in unprinted or solid colour areas.
Disadvantages: Prices are determined by the size of the area to be embossed. Avoid fine detail and fine lines and keep everything bold, allow enough space between text to achieve the raised or lowered effect, remember the block has to push the thickness of the substrate into the image and if there are lines or text thinner than the substrate it wont work.
Embossing is a process by which blocks (dies) are used to stamp a relief image and Debossed is a process by which blocks (dies) are used to stamp a sunken image. Embossing requires both male and female magnesium blocks while debossing requires just a male block.
Advantages: Gives a lift to the printed surface and is ideally suited to heavier uncoated stocks. We find embossing works best in unprinted or solid colour areas.
Disadvantages: Prices are determined by the size of the area to be embossed. Avoid fine detail and fine lines and keep everything bold, allow enough space between text to achieve the raised or lowered effect, remember the block has to push the thickness of the substrate into the image and if there are lines or text thinner than the substrate it wont work.
Folding is a major part of print finishing from brochure folding to complex pharmaceutical folded inserts. We are one of the very few printers in Ireland that can produce a closed gate fold.
Avoid: Multiple folds that trap air within the folded signature and cause creases to form. Heavy stocks are best kept to same direction folds like parallel or roll folds.
Foiling is where a block made from the image required is heated and stamped through a thin foil onto the substrate.
Advantages: Gives a lift to the printed surface that printing alone cannot give.
Disadvantages: Finer detailed design can be an issue, Pantone foils are not 100% opaque.
Lamination / Celloglaze is the process of laminating a thermal (pre-glued) plastic film (25 micron) of either gloss or matt to the printed matter.
Advantages: Protects and prevents cracking of surface coating which is ideal for covers of brochures.
Disadvantages: It does add additional cost and production time, difficult to laminate weights under 170gsm.
Scoring is the term that refers to the process in which a crease is applied to paper to facilitate the folding of heavy stock also to prevent cracking of the coating on the fold. The process requires a male rule and a female chase.
Advantages: Makes folding heavy stock easier and minimises cracking of the paper coating.
Disadvantages: Not very successful on lighter stocks and adds an additional operation to the finishing process.
