Trouble Shooting Guide on Paper Problems for the Bookbinder
I was told that this issue of WT will focus on substrates – paper , board etc that get bonded together.
The paper upon which the book is produced is usually chosen by the publisher or book designer. The criteria is that it should be ideal for the printing equipment to be used and the print quality required. Unfortunately the best papers for printing are almost invariably the least favorable for adhesive binding.
The best paper to bind is fibrous, uncoated and fairly bulky – eg Newsprint, Antique Wove types. Short fibre - coated papers (such as art paper) do not bind, easily. This type of paper is difficult to bind with single roller gluing systems.
Testing for Paper Grain : There have been many discussions on the subject in the past, but just to recap on this as well as to understand more – The paper you intend to bind contains a grain, which is created by the flow of the pulp stock as it is suspended on the endless wire belt of the paper mill (machine)
Fig (2.1) Grain Direction
1. Pinch the paper between the fingernails
2. Draw lightly down the edge
3. There will be no stretch with grain but stretch mark across the grain
Fig 2.1 (cont)
Long Grain - This is cut lengthwise from the paper web so that the direction of grain runs parallel to longer side
Short Grain – is cut crosswise from the paper web so that the grain runs across the shorter side.
The best bind is obtained when the grain of paper runs parallel to the spine of the book. Cross grained paper can be only bound (as a last resort) provided the paper is fibrous and not too heavy (low gsm)
Given below are a few typical issues related to paper and the solutions.
Cocking or wavy edges - Over-dried paper will steadily increase its relative humidity, thus the problem will grow. Keep drying temperatures as low as possible; remoisten on the press.
Cracking at the fold - Over dried with intense heat, makes the coating medium brittle. Remoisten where possible or use a water line.
Fibre lift - Mechanical fibres that contain lignin expand under heat; this can give glossy papers a rougher surface. Keep drying temperatures low. Ask the buyer to choose wood-free paper.
Poor page strength - Good results one week, poor results the next and yet bound on the same machine, same adhesive and operator. Intense drying makes the fibres brittle, i.e. LWC paper is 50 per cent mechanical pulp and 50 per cent wood free. Brittleness in the ground wood can reduce the page flex and pull strength by half.
Stepping after trimming Over-dried and mixed paper stocks. Growth will vary in speed and amount due to the relevant humidity. Keep drying temperatures to a minimum, re-moisten on the press, and do not use mixed papers.
Wrinkles on Spine after the trimming operation –
Perfect Binding, if not perfect in all aspects is to deliver perfectly smooth spine. Wrinkles on book spine are caused due to many reasons, including the cover stock.
Spin crease - Spongy spine. Increase nip pressure on the binding machine. Check guillotine clamp pressure. Investigate the grinding angle of blade. Test for damp cover board due to aqueous links or varnishes. Monitor board de-lamination and test other boards on the same work.
Wednesday, November 22, 2006
Tuesday, November 21, 2006
Werner Rebsamen On Binding Methods
For Welbound Times by Werner Rebsamen Professor Emeritus RIT
Which Binding Method is Best?
One of my favorite sayings always was “Think about the Binding Method First – not Last!” Why would I make such a statement in my lectures? Well, with a unique testing facility at hand, we have seen too many failed products. I could write a book about it.
Before you do anything else, try communicating with a binder first. These experts have many “tricks” up their sleeves, most often effective tools for stretching a clients budget.
Only good planning prevents costly mistakes. How a book or other product will be bound dictates the imposition. Just imagine if you forget the extra paper allowances for a perfect bound or a mechanical binding. We did discuss the correlation of the guides to maintain perfect registration. Well I could go on but to avoid problems, good communication is perhaps the best advice to avoid costly mistakes.
Now, what binding types are available? That is of course a most valid question. While employed at RIT in education, next to our under- and graduate courses, we did conduct 100’s of industry seminars. My favorite was a three day seminar I chaired and taught in behalf of the Book Manufacturer’s Institute. Twice a year, for 23 years, I had interesting dialogs with people employed in the publishing industry, suppliers or manufacturers of books. Now back to the question on binding types. In order to select an appropriate method of binding, you must ask the question, what is the end-use purpose? If it is a cook book, should you consider perfect binding? Well, we have seen such cross-grain cook books going to the grave yard, 40’000 of them, all hardcover bound books, acting like a mouse trap! The first pre-requisite for such a product is of course that it does lie flat, unassisted by hands. Ideal for such a product would be a mechanical binding or if it need to be hardcover bound, select book sewing but make sure that the binders do not use a stiff hotmelt on the spine! First, do ask for an example and evaluate it. End-use performance is perhaps the most important item. Advanced samples let you be the judge.
Publishing production managers are under great pressure in regards to budgets. That is understandable but again, they should always keep in my, that a particular product has a specific function. For example, an art or a so-called coffee table book with lots of color works. Such a product must lie flat to be enjoyed which means, a production planner must be careful when selecting paper, must make sure the grain direction of the paper is parallel to the binding edge etc..
Below are some hints for choosing the right method of binding:
Saddle Stitch – Booklets, pamphlets, magazines, catalogs etc..
Advantages - they do lay flat, are inexpensive, use self or separate covers.
Gate folds and foldouts are possible. Widely available, most printers can do it in-house.
Limitations - are longevity, not recommended for heavy end-use. Lacks printable spine although that technology is now available. Thickness is another limitation.
Loop stitched versions to be placed into ring binders are available at some binders.
Side Stitch – Manuals, brochures, inexpensive products or for items which must last.
Advantages - A fast and inexpensive method. Strong Binding.
Limitations - Openability and thickness.
This method is this days largely replaced with perfect binding.
Spiral Binding – Available in wire or plastic. Excellent for presentation documents etc..
Advantages – use virtually any materials. Paper-grain or weight does not matter. Folds over 360 degrees. Does always lie flat.
Limitations – not as sturdy as double loop wire. If crushed, pages no longer turn. Cross-over designs do not align.
Double Loop Wire – Cook books, calendars, reference manuals etc..
Advantages – very versatile and durable. Lays flat. Can include hanger. Perfect alignments.
Sheets turn easily with all kinds of papers, boards etc.. Can be case-bound.
Limitations – If wire is crushed, it will not return to its original shape.
Plastic Comb – Reports, documents, reference materials etc..
Advantages – Widely available and economical. Imprinting of comb possible for spine identification. Can be re-opened to add pages (tool required)
Limitation – if comb is crushed sheets get damaged. Sheets do not turn past lay-flat position. Not for heavy end-use.
Perfect Binding – Reports, manuals, brochures, books, catalogs etc..
Advantages – Most economical for thicker products which can no longer be saddle-stitched.
Good overall look. Printable spine. With the right grain direction, good longevity.
Limitations – Does not lay flat. Minimum thickness is 3mm.
Lay Flat – Otabind or RepKover. soft-cover books with open spines similar to hard cover bindings are ideal for technical manuals cook books music notes etc.
Advantages – Lays flat if adhesive bound with PVA or PUR. Spine does not crease.
Used were hands-free reading is important.
Limitations – Not recommended for coated stock unless text-block is sewn or PUR adhesive is used.
Sewn Bindings – Through the fold, used for quality, most often case-bound works.
Advantages – Books lay flat. Simply the best quality and durability of any method.
Can bind a wide range of thicknesses.
Limitations – virtually none, more expensive than most other binding methods.
Saddle Sewn – Children books, documents such as passports etc..
Advantages – Far superior to saddlestiching. Ideal for thin books. Good openability, does lay flat. Exceptional page-pull strength.
Limitations – Should not be used on projects over 5mm thick.
Side-Sewn – Children and text books were exceptional strength is required
Advantages – Ideal for school text books and children books. Virtually indistructable.
Limitation – Openability, requires extra space for margins. Does not lay flat.
Case bound – Can be used in combination with adhesive, sewn or mechanical bindings.
Best for books of virtually any kind, reference, children, school, library, legal etc..
Advantages – Superior quality and durability. Good looks. A justification for a much higher price = increased revenues.
Limitations – High cost, the most expensive of all binding types discussed.
The best advice I could give to publishers was, always prepare a dummy, using the actual paper stocks in their correct weights and finishes. Carefully choose covering materials. Suppliers are eager to work with you in this regard. If individual shipping is involved, make sure you weigh the finished sample book. We had court-cases where just a few grammes tipped the postmasters scale to a higher category.
And finally as stated earlier – first, before you do anything else, communicate with the binder!
Which Binding Method is Best?
One of my favorite sayings always was “Think about the Binding Method First – not Last!” Why would I make such a statement in my lectures? Well, with a unique testing facility at hand, we have seen too many failed products. I could write a book about it.
Before you do anything else, try communicating with a binder first. These experts have many “tricks” up their sleeves, most often effective tools for stretching a clients budget.
Only good planning prevents costly mistakes. How a book or other product will be bound dictates the imposition. Just imagine if you forget the extra paper allowances for a perfect bound or a mechanical binding. We did discuss the correlation of the guides to maintain perfect registration. Well I could go on but to avoid problems, good communication is perhaps the best advice to avoid costly mistakes.
Now, what binding types are available? That is of course a most valid question. While employed at RIT in education, next to our under- and graduate courses, we did conduct 100’s of industry seminars. My favorite was a three day seminar I chaired and taught in behalf of the Book Manufacturer’s Institute. Twice a year, for 23 years, I had interesting dialogs with people employed in the publishing industry, suppliers or manufacturers of books. Now back to the question on binding types. In order to select an appropriate method of binding, you must ask the question, what is the end-use purpose? If it is a cook book, should you consider perfect binding? Well, we have seen such cross-grain cook books going to the grave yard, 40’000 of them, all hardcover bound books, acting like a mouse trap! The first pre-requisite for such a product is of course that it does lie flat, unassisted by hands. Ideal for such a product would be a mechanical binding or if it need to be hardcover bound, select book sewing but make sure that the binders do not use a stiff hotmelt on the spine! First, do ask for an example and evaluate it. End-use performance is perhaps the most important item. Advanced samples let you be the judge.
Publishing production managers are under great pressure in regards to budgets. That is understandable but again, they should always keep in my, that a particular product has a specific function. For example, an art or a so-called coffee table book with lots of color works. Such a product must lie flat to be enjoyed which means, a production planner must be careful when selecting paper, must make sure the grain direction of the paper is parallel to the binding edge etc..
Below are some hints for choosing the right method of binding:
Saddle Stitch – Booklets, pamphlets, magazines, catalogs etc..
Advantages - they do lay flat, are inexpensive, use self or separate covers.
Gate folds and foldouts are possible. Widely available, most printers can do it in-house.
Limitations - are longevity, not recommended for heavy end-use. Lacks printable spine although that technology is now available. Thickness is another limitation.
Loop stitched versions to be placed into ring binders are available at some binders.
Side Stitch – Manuals, brochures, inexpensive products or for items which must last.
Advantages - A fast and inexpensive method. Strong Binding.
Limitations - Openability and thickness.
This method is this days largely replaced with perfect binding.
Spiral Binding – Available in wire or plastic. Excellent for presentation documents etc..
Advantages – use virtually any materials. Paper-grain or weight does not matter. Folds over 360 degrees. Does always lie flat.
Limitations – not as sturdy as double loop wire. If crushed, pages no longer turn. Cross-over designs do not align.
Double Loop Wire – Cook books, calendars, reference manuals etc..
Advantages – very versatile and durable. Lays flat. Can include hanger. Perfect alignments.
Sheets turn easily with all kinds of papers, boards etc.. Can be case-bound.
Limitations – If wire is crushed, it will not return to its original shape.
Plastic Comb – Reports, documents, reference materials etc..
Advantages – Widely available and economical. Imprinting of comb possible for spine identification. Can be re-opened to add pages (tool required)
Limitation – if comb is crushed sheets get damaged. Sheets do not turn past lay-flat position. Not for heavy end-use.
Perfect Binding – Reports, manuals, brochures, books, catalogs etc..
Advantages – Most economical for thicker products which can no longer be saddle-stitched.
Good overall look. Printable spine. With the right grain direction, good longevity.
Limitations – Does not lay flat. Minimum thickness is 3mm.
Lay Flat – Otabind or RepKover. soft-cover books with open spines similar to hard cover bindings are ideal for technical manuals cook books music notes etc.
Advantages – Lays flat if adhesive bound with PVA or PUR. Spine does not crease.
Used were hands-free reading is important.
Limitations – Not recommended for coated stock unless text-block is sewn or PUR adhesive is used.
Sewn Bindings – Through the fold, used for quality, most often case-bound works.
Advantages – Books lay flat. Simply the best quality and durability of any method.
Can bind a wide range of thicknesses.
Limitations – virtually none, more expensive than most other binding methods.
Saddle Sewn – Children books, documents such as passports etc..
Advantages – Far superior to saddlestiching. Ideal for thin books. Good openability, does lay flat. Exceptional page-pull strength.
Limitations – Should not be used on projects over 5mm thick.
Side-Sewn – Children and text books were exceptional strength is required
Advantages – Ideal for school text books and children books. Virtually indistructable.
Limitation – Openability, requires extra space for margins. Does not lay flat.
Case bound – Can be used in combination with adhesive, sewn or mechanical bindings.
Best for books of virtually any kind, reference, children, school, library, legal etc..
Advantages – Superior quality and durability. Good looks. A justification for a much higher price = increased revenues.
Limitations – High cost, the most expensive of all binding types discussed.
The best advice I could give to publishers was, always prepare a dummy, using the actual paper stocks in their correct weights and finishes. Carefully choose covering materials. Suppliers are eager to work with you in this regard. If individual shipping is involved, make sure you weigh the finished sample book. We had court-cases where just a few grammes tipped the postmasters scale to a higher category.
And finally as stated earlier – first, before you do anything else, communicate with the binder!
PERFECT BINDING WITH HOT MELT - A Check List
We will attempt to make a list of “Dos and Don’ts” that can provide guidance to a production manager while planning a perfect binding job.
What are hot melt adhesives?
Hot melt are 100% solid thermoplastic materials that flow when heated, the final bond is formed when the temperature has fallen to ambient conditions
Advantages: Capable of bonding widest possible range of paper stocks and fast speed production, short compression time and rapid set speed, moisture resistance reduced maintenance and clean up costs.
Book components and how do they affect quality of books.
1) Paper stocks
The best paper to bind is fibrous, uncoated and fairly bulky; e.g newsprint. Short fibre, coated papers such as art stocks and some coated cartridge papers do not bind well . This is due to low fibre content , high %ge of clay , which do not present a good surface for adhesion . This type of paper is particularly difficult to bind with one shot systems as they do not penetrate the actual paper fibre itself, but rely totally on mechanical anchorage to the notched spine.
2) Paper grain :
The best bind is obtained with the grain of paper parallel to the spine of the book. Cross grained can also be bound
Provided the paper is of fibrous type.
Combination of cross grain together with heavy coating is very difficult situation to handle. If one introduces yet another adverse factor that of high grammage (100 g.s.m and upwards) then binding of that book will be almost impossible.
Cross grain parallel grain
3) Cover stocks or lining material :
Covers should be dry, unvarnished and unprinted on the spine or side gluing area.
How to choose right types of adhesives :
1) Machine : Make , method of application ,measurement of time from application to compression and then to next operation
2) Substrates to be bonded , subsequent operations.
3) End use of final product e.g export quality ,exposure to hot and cold conditions.
4) Cost, current products used , color and odor ,storage .
5) Plant conditions , humidity ,housekeeping etc.
Things to avoid :
1)Avoid using damp stocks.
2)Avoid starving the adhesive applicator
3)Avoid mixing of two adhesives.
4)Avoid using very cold materials.
Charateristics of typical BB HMA :
1) Viscosity profile :Ideally from 2000 to 4000 cps
2) Good flexibility : good lay flat properties, good stretching while opening the book, good rounding of book block.
3) Good tensile strength which will ensure tough product and high page pull values.
Cool bind Bookbinding HMA :A cool alternative to bindery operations.
Cool HMA delivers: Fast trimming, higher mileage ,low operating temperatures ,great viscosity stability , hence increased productivity and energy savings, less down time ,longer equipment life , less burns, low volatiles etc.
We will attempt to make a list of “Dos and Don’ts” that can provide guidance to a production manager while planning a perfect binding job.
What are hot melt adhesives?
Hot melt are 100% solid thermoplastic materials that flow when heated, the final bond is formed when the temperature has fallen to ambient conditions
Advantages: Capable of bonding widest possible range of paper stocks and fast speed production, short compression time and rapid set speed, moisture resistance reduced maintenance and clean up costs.
Book components and how do they affect quality of books.
1) Paper stocks
The best paper to bind is fibrous, uncoated and fairly bulky; e.g newsprint. Short fibre, coated papers such as art stocks and some coated cartridge papers do not bind well . This is due to low fibre content , high %ge of clay , which do not present a good surface for adhesion . This type of paper is particularly difficult to bind with one shot systems as they do not penetrate the actual paper fibre itself, but rely totally on mechanical anchorage to the notched spine.
2) Paper grain :
The best bind is obtained with the grain of paper parallel to the spine of the book. Cross grained can also be bound
Provided the paper is of fibrous type.
Combination of cross grain together with heavy coating is very difficult situation to handle. If one introduces yet another adverse factor that of high grammage (100 g.s.m and upwards) then binding of that book will be almost impossible.
Cross grain parallel grain
3) Cover stocks or lining material :
Covers should be dry, unvarnished and unprinted on the spine or side gluing area.
How to choose right types of adhesives :
1) Machine : Make , method of application ,measurement of time from application to compression and then to next operation
2) Substrates to be bonded , subsequent operations.
3) End use of final product e.g export quality ,exposure to hot and cold conditions.
4) Cost, current products used , color and odor ,storage .
5) Plant conditions , humidity ,housekeeping etc.
Things to avoid :
1)Avoid using damp stocks.
2)Avoid starving the adhesive applicator
3)Avoid mixing of two adhesives.
4)Avoid using very cold materials.
Charateristics of typical BB HMA :
1) Viscosity profile :Ideally from 2000 to 4000 cps
2) Good flexibility : good lay flat properties, good stretching while opening the book, good rounding of book block.
3) Good tensile strength which will ensure tough product and high page pull values.
Cool bind Bookbinding HMA :A cool alternative to bindery operations.
Cool HMA delivers: Fast trimming, higher mileage ,low operating temperatures ,great viscosity stability , hence increased productivity and energy savings, less down time ,longer equipment life , less burns, low volatiles etc.
GUK Comes to INDIA
Griesser and Kunzmann (GUK) GmbH & Co. KG, one of the world’s leading manufacturers of Folding Machines has arrived in India. More than 50 (used) GUK machines are already in India and it is in this context GUK decided to strengthen its operations here. To begin with, GUK will have a partnership with the Welbound Team for Sales and Service of their range of Folding machines. The key service engineers of Welbound have already undergone a comprehensive training at the GUK Factory in Wellendingen, Germany.
GUK was founded in 1948 by Anton Kunzmann and Karl Griesser. Early on their formation they also ventured into turning parts manufacturing for the Automobile Industry. They have a State of the Art plant for turning parts manufacturing, with very high level of in process inspection and QC systems and this has helped in their key business of folding machines manufacturing.
From 14 construction lines GUK combine more than 100 variations of machines. These machines are used successfully in every place where paper is made in shape. GUK is well known in the world market for making custom made solutions for complicated applications. Their products find application in the printing industry, pharmaceutical industry, packaging industry, bookbinding, lettershops, administrations, bankings etc. Till date more than 40000 GUK machines work in various parts of the world.
Of the various family of machines manufactured by GUK, there are (a) All parallel (Pocket) folders (b) Combination folders (c) Pharmaceutical Insert makers with on line taping system (d) Mailing systems (e) Sheet feeders (f) Reel Feeders, and the list goes on and on. And they come in all formats. Their in house R&D and understanding of the process of folding has lead to such unique developments like 12 pockets (12 parallel folds) in one stage. What stand out as major strengths of GUK are (a) Capability to provide custom made solutions that can handle any type of Fold/Application (b) Integrating accessories from other suppliers to provide complete solutions. Current day folding machines have grown beyond the simple application of folding paper and evolved into complete print finishing equipment – with on line gluing/ punching/ taping etc. In such a context GUK’s strengths are helping it achieve market prominence.
GUK’s custom made Mailing Systems have provisions for folding, gluing, selective perforation, Card insertion-pasting, taping,
The Sales and Service arm of the Welbound group has inked an Agreement with GUK for supply of their extensive range of folding and mailing systems to the Indian buyer. Welbound’s understanding of folding machines combined with the special training provided by GUK will go a long way in developing the folding application engineering in India.
For further information on GUK products contact : Impel Marketing Services, 112 East West Ind Centre, Safedpool, Kurla Andheri Road, Mumbai -400072. Email: welbound@gmail.com . Tel : +91-22-28596960, 28597919.
Photo caption : K C Sanjeev with Bernd Kunzmann and Ms Silke Flaig of GUK at the recently concluded Open House at GUK factory in Germany
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