Allied Bindery

Spine Perforations – Great Advantage or Wasted Effort?

Allied — Tue, 21 Feb 2012 18:25:40 +0000

Printers often incorporate spine perforations into the printed signature, whether folding a sheet fed form or delivering directly from a web press. The perforation provides a distinct advantage to the folding process. A spine perforation allows air to escape during the folding process, reducing the chances of wrinkling, bottling or shingling. This, in turn, results in a better looking final product.

A significant risk that is often overlooked by a folder operator or web press operator is the size of the perforation blade or wheel. If a perforation is too aggressive, i.e., lots of perf, not much paper remaining; the spine of the signature may break apart during the collation/gathering process at the bindery.

The amount of paper that is left intact on the spine provides the only strength to hold the spine together during the collation process. The mechanical gathering process in the bindery requires that the spine of a signature be pulled down into the collator grippers using vacuum suckers. If the perforation blade or wheel used at the folder or press was too aggressive, the paper will peel apart at the spine of the signature when the vacuum suckers begin to the pull the form into the grippers.

Once this happens, there is often no alternative other than to hand feed the affected signatures. Hand feeding or hand collation results in increased expense and decreased production speed on the binder. This is a phone call that the bindery does not want to make and the printer doesn’t want to receive.

A quick way to check the strength of the perforation is to flex and jog a handful of signatures at the folder or web press. If the perforations show any indication of splitting or breaking apart during the hand jogging routine, they will break and fail during the mechanical collating process. If this is noticed, it is time to change to a less aggressive perforation wheel or blade, thus helping to avoid unanticipated problems and additional charges during the binding process.

Notch Binding – Key Planning Tips

Allied — Thu, 02 Feb 2012 01:29:52 +0000

Notch Binding – Key Planning Tips

Notch Binding has long been a preferred choice of printers when perfect binding coated stocks, cross grain stocks and multiple paper types within a book. Notch binding has also provided an advantage of saving paper, since a spine grind margin is not required. When considering or planning for a notch bind project, there are several things to keep in mind, so binding problems are not inadvertently created.

It is imperative that a notch perforation wheel is used to perforate the spine when folding signatures for a notch bind project. A notching perforation wheel is designed to remove more paper when perforating, leaving a larger, cleaner channel for adhesive to flow into when the book is being bound. Trying to use a perforation wheel other than one designed specifically for a notch bind, will result in weak or non-existent adhesion strength in the final book.

Folding accuracy is crucial. A spine fold that is slightly off center will narrow or close the notch channel in the folded signature. This will create an impediment to the adhesive flowing up through the notch channel and reaching the innermost leaves of the signature. The result will be inadequate binding strength of the inner leaves of the signature. The folder operator should be able to look directly into the notches of a finished signature and see an open and clear channel for adhesive flow into the center of the signature.

The higher the signature page count; the more important the accuracy and cleanliness of the notch becomes. Sharp perforation wheels and notching blocks must be used to insure that the final binding strength is adequate.

During the binding process, the Binder Operator should perform page pull tests on the innermost leaves of each signature. Structurally, this will be the weakest point of adhesion. Ensuring a strong page pull result on the inner most leaves will help guarantee a successful binding project.

The advent and success of PUR adhesives provides customers with other binding alternatives. Allied Bindery’s Operations and Estimating Professionals will be pleased to explain the alternatives and recommend a binding solution that is best suited to your project.

Allied Bindery Wins Tweddle Group 2011 Supplier Excellence Award

Allied — Tue, 24 Jan 2012 20:32:48 +0000

What’s New:

Allied Wins Tweddle Group 2011 Supplier Excellence Award

for

Outside Bindery Services, Again!

The Allied team is grateful and honored to once again receive this prestigious award. We are very pleased our quality and value proposition is recognized and valued by those who matter most, our customers.

The Supplier Excellence Award is given annually to recognize an outside bindery who achieves the highest performance in the Tweddle Group Vendor Rating System. To promote supplier chain continuous improvement, Tweddle Group tracks the performance of bindery, outside print and paper vendors via a point-based system called the Vendor Rating System. Vendors are rated on quality, delivery, service, use of a certified quality system and participation in a cost reduction program.

Allied Bindery’s leadership and expertise is rooted in its core philosophy and company mission of “ Pursuing Excellence….Delivering Results! For The Benefit of our Customers.”

High Profile, High Use – PUR is the Only Choice

Allied — Fri, 13 Jan 2012 17:43:53 +0000

Polyurethane Reactive (PUR) adhesive has become the adhesive of choice for many printers and trade binderies during the past several years. It has been particularly popular when matched with coated stock projects. One of the most common questions that is posed to us is “When does it make sense to use PUR?”

Allied Bindery was an industry leader for the introduction of PUR and we have experienced a significant growth in the use of PUR during the past several years. We recommend that the following attributes be used as a guideline for choosing PUR for your binding projects:

Coated Stock – particularly 70# basis weight and greater. The heavier the basis weight of the stock, the more stress that is placed on the glue line when pages are flexed (turned) by the end user.

Cross Grain Stocks – whether coated or uncoated. A short grain stock simply does not have the fiber exposure and fiber length to create a strong page pull or flex result when paired with an Ethyl Vinyl Acetate (EVA) adhesive.
Mixed Stocks – PUR is the superior choice when a project utilizes mixed text stocks with a variety of fiber characteristics.
Synthetic Stocks – With no fiber available, an EVA will quickly fail. PUR adheres via a chemical melding versus a “mechanical” glue bind. PUR is the best choice for synthetic stocks.
Full Ink Coverage – In general, inks and most coatings will not repel PUR as they will EVA adhesives. If your project includes a full ink or coating coverage into the spine grind area, consult with your Allied Bindery representative so that we can guide you with respect to knock outs.
High Use Products – Catalogs, Directories and Text Books are examples of products subject to a high usage rate, which must also stand the test of time. PUR provides vastly superior page pull and flex results that allow for a high usage rate without the spine breaking down.
Extreme Heat or Cold – EVA adhesives will cold crack at just less than 40 degrees Fahrenheit and re-soften at 120 degrees Fahrenheit. If you have products that will be stored or used in extreme cold or hot climate conditions, PUR provides superior results.

Cross Grain Covers – Are You Saving Money or Creating a Headache?

Allied — Thu, 29 Dec 2011 16:07:56 +0000

Depending upon the final trim size of a binding project and the sheet size capacity of the printing press, printers often make decisions to use a cross grain sheet when printing covers for a stitching or binding project. Although this decision may save on the cost of paper, it may also create several cosmetic or functional issues that may lead to additional downstream costs. Several things should be considered before deciding to print a cross grain cover.

Spine and Hinge Score cracking is a common complaint when cross grain covers are used. If the cover design requires full ink or dark ink coverage, cracking along the spine or hinge score becomes highly visible and can be viewed as an objectionable cosmetic defect by the customer. The best opportunity to minimize this type of problem is to die score the spine and hinge score areas of the cover. A die score is a superior choice to the wheel score that may be provided by a perfect binder or saddle stitcher cover feeder. The die score, however, increases the cost of the project and may offset any savings generated by the use of a cross grain sheet. Additionally, if the requirement to die score is not identified until after the cover has been shipped to the Bindery, both the additional cost and additional processing time will be unexpected.

Cross grained covers applied to a perfect bound book will likely result in a series of waves along the length of the spine. Once the cover is adhered to the body of the book, any moisture that may be absorbed by the cover stock can expand the paper grain. Since the cover will be held in place by adhesive along the spine, waviness will often be created as relative humidity is absorbed into the cover stock. Although the book remains functional, this cosmetic imperfection may leave a customer dissatisfied with the end result.

Involving the Sales and Planning Professionals at Allied Bindery can help you avoid problems such as recognizing or avoiding potential problems with cross grain covers. Give us a call and let us help you achieve your customer’s expectations.

The Advantages of Split Binding

Allied — Mon, 12 Dec 2011 20:32:05 +0000

Often times, your project may have multiple end uses. As such, there are occasions when one specific binding style may not fit all of your requirements. For instance, a perfect bound sports media guide may be the desired binding style for the fans in the stands. However, a sportscaster or reporter may require a binding style that opens and lies perfectly flat without being held in place. Similarly, a perfect bound book may work well for a student, however, the instructor may want a version in which specific sections may be removed and/or updated over time. When your project
requires a range of use such as these examples, a split binding production approach can be used to solve the challenge.

Simply stated, split binding is the utilization of two or more binding methods to achieve the end use requirements of your customers. In the example of the sports media guide, combining perfect binding and a mechanical binding technology such as coil binding, addresses the needs of both end user groups. In the case of the educational media or text book, combining a perfect bind design for the student, with a loose leaf option for the instructor achieves the use requirements for both.

Understanding the end use requirements of your customer, in combination with the finishing capabilities of your trade bindery, may allow you to offer multiple binding options that achieve separate and distinct requirements of the end users.

Allied Bindery routinely produces projects that require a combination of perfect binding and mechanical binding, or perfect binding and loose leaf options. Involving the Sales and Planning Professionals at Allied Bindery can help you determine the binding options that will work best for your customer’s requirements.

Planning for Layflat Perfect Bound Books

Allied — Thu, 01 Dec 2011 17:12:10 +0000

Your customer has just requested a perfect bound book with enhanced capabilities to lie flat when opened. You check your list of trade
bindery service providers and see that some of them promote the ability to
produce Layflat Binding (or Stayflat or Otabind). Problem solved, right?

Not necessarily. There are several critical planning steps that must be considered during the design and prepress stages of the project that ultimately determine the cosmetic and functional success or failure of the book.

A successful Layflat binding style is accomplished by building the book so that the spine of the book block is not attached to the spine of the book cover as with a standard perfect bound product. The Layflat book block must first be adhered to a fabric liner rather than a book cover. The bound book block will then be attached to the cover between a pair of hinge scores specifically placed on the front and back cover. This design allows the spine
of the book cover to separate from the book block when the book is opened,
allowing the spine of the book block to float above the book cover. This design reduces resistance and allows for an enhanced Layflat characteristic when the book is opened.

In order to build a successful Layflat product, design and prepress planning must incorporate specific requirements for hinge scores, graphics and text placement on the covers and interior text pages. Design requirements must also provide consideration for cross alignments, page borders, and if necessary, drill hole placement. Failure to plan for these critical characteristics will result in an unhappy customer.

The Sales and Planning Professionals at Allied Bindery are prepared to assist you with the critical planning requirements for Layflat Binding.
Give us a call and let us show you how we can help ensure a successful
project for you.

To Stick or Not to Stick – UV Coating versus Binding Adhesives

Allied — Fri, 18 Nov 2011 16:40:58 +0000

Incorporating UV Coating into perfect bound print projects is a great opportunity to enhance the visual and cosmetic characteristics of a printed piece. Understanding interaction between UV Coating and binding adhesives will help printers avoid unpleasant surprises in the finished product.

A key ingredient in the chemical make up of UV Coating is silicone. Silicone provides a degree of “slippery-ness” in the coating. The amount of silicone in UV can have a dramatic impact on the ability of the binding adhesive to stick to or repel from the UV coated material. Depending upon the amount of silicone used in the chemical make up of the UV Coating, adhesion problems may result. In other words, more silicone equals more binding related challenges. Since the bindery will not have any knowledge as to the silicone content in UV coated materials, problems will likely not be identified until the binding process is underway or complete.

Binding adhesion problems with UV coating may appear in a number of different ways. If the UV coating is a flood coat extending into the spine grind area and the UV coating contains a high level of silicone, there may be total adhesion failure at the spine. The silicone content will repel the binding adhesive and not allow a stable or consistent adherence between text paper stock, the spine adhesive and the book cover.

A UV coating with a lower level of silicone content may allow for adequate adhesive strength, but may allow for adhesive migration up between text pages. Adhesive that migrates as little as 1/16” up from the spine will result in paper fibers tearing between pages as the book is opened. Although the binding strength is adequate, the cosmetic result is poor and will be unacceptable to the customer.

When planning for a page or pages utilizing flood UV coating in a perfect bound book, make sure to knock out the spine grind area. Eliminating the UV coating in the spine grind area will help insure an appropriate binding strength, while eliminating the potential for adhesive migration between pages, thus ensuring the quality level that you and your customer desire.

Involving the Sales and Planning Professionals at Allied Bindery can help you avoid problems such as recognizing or avoiding potential production challenges with UV Coating. Give us a call and let us help you achieve your customer’s expectations.

Accurate Estimates Equals No Surprises!

Allied — Mon, 07 Nov 2011 20:12:02 +0000

It all comes down to accurate specifications! The better the detail, the more accurate the estimate! No one likes surprises; particularly when it comes to final pricing of a project. Providing as much detail as possible at the quoting stage is a key to providing estimates that will still be accurate when the production process begins.

Often times, the initial request for quote is referred to as “budget” or “ballpark”. Allied Bindery will provide a quote that is accurate to the specifications that are provided. In some instances, the actual job
requirements can be significantly different than the original “budget”
estimate. If the purchase order contains different specifications than the original estimate, the estimate will need to be validated or revised.

Many times, specification changes may have a slight impact on final pricing. It may be that the basis weight of the paper was changed, resulting in costing and pricing changes in the amount of adhesive, cartons or shrink wrap film that is required. These are generally minor revisions to cover
material costs. Sometimes, the change may be significant. For example, a
binding project could have been quoted as two-up. In reality, the final project could be a come & go format, having a significant impact on labor costs. Maybe you will need a partial quantity bound and delivered before the balance of all material is available. This will have an impact on set up costs, since an additional set up will be required. These costs tend to be higher and need to be communicated to your customer as soon as possible.

In all cases, when a project becomes live and a purchase order is provided, our Estimating/Order Entry specialists will review the scope of the purchase order in comparison to the original estimate. If any changes or revisions are required, you will be contacted prior to the start of the job so that you will have any updated pricing that is required. It is important to note that all estimates are tentative, pending the actual specifications for a project.

Do’s and Don’ts When Planning Oblong Trim Size Projects

Allied — Thu, 20 Oct 2011 15:12:00 +0000

Sometimes, from a visual perspective, nothing catches the eye like an oblong book or brochure design. Because an oblong trim size can be more difficult to fold, stitch and bind, there are a number of planning tips that must be considered to make the production of your project flow smoothly.

Consider the benefits of printing and binding your oblong project in a multiple-up format. Oblong projects usually combine wide pages with narrow (short) spine heights, presenting feeding and travel difficulties
on stitchers and binders. Planning your oblong project to be printed and bound in a two-up, three-up or more format, provides the bindery with a much more stable product to feed through collators and along saddle or gathering chains. A multiple-up format often reduces production costs, both in the printing and binding process, while insuring a higher level of cosmetic quality.

Make sure that you understand the minimum and maximum size limitations of the bindery equipment when selling, planning and printing oblong projects. Projects may look great right through the printing process, but finding out that one of the dimensions is either too small or too large to feed through bindery equipment can result in a very expensive and embarrassing mistake.

Consider a two-up, oblong format or perfect binding, Allied Bindery can assist you with creating Come & Go layout formats on many jobs, saving considerable cost through the printing, as well as the bindery production process. Having book saws on both of our binding lines allows for a high level of productivity, while providing significant cost and price advantages to our customers.

Oblong projects often require folding layouts that include accordion and double parallel folding in consecutive folding gates. Allied Bindery can help you plan the accordion fold layout to minimize the potential for dog-ears that may occur during the subsequent double parallel folds required to finish a signature.

Involving the Sales and Planning professionals at Allied Bindery can help you avoid problems such as recognizing or avoiding potential production challenges with oblong projects.