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Saddle stitching is often seen as a “simple” binding solution for many applications. However, that doesn’t mean the design of these applications has to be simple. One way to spice up a saddle stitched book is to incorporate pull-out or foldout panels, which can be designed as either gate, roll or accordion folds.
Here are a few tips to keep in mind when planning stitched products that include these folds:
 To Glue or Not to Glue
To keep the folded panels from unraveling during stitching, some books with foldout panels may need to be glued. The amount and placement of the glue depends on the type of fold:
Accordion folds - Glue should be placed in the trim-off areas at the head and foot to keep an accordion fold from flopping outward. In addition to the normal 1/8” trim margins, leave at least an extra 3/8” margin for the glue, which will be removed during head and foot trimming. Don’t forget that all other signatures should have the same margin.
Gate and roll folds - Spot glue in the trim area is typically not necessary on gate or roll folds. However, there are two exceptions: When a light stock is used, and when there is a short foldout panel. Stocks heavier than 5 pt. should have enough weight to fall correctly on the saddle; anything lighter may fly open, requiring a spot of EZ-release glue. Multiple panels on one side may also require a glue spot to keep from unraveling when opened due to the extra weight.
Although full-size gate-fold panels should pose no problems, short gate flaps may flop open during feeding. Again, a spot of EZ-release glue will be needed to hold the short panels closed during stitching.
The Rickard Advantage
With proper planning and communication, even the most complex folding sequences can be included in a stitched booklet and produced efficiently. For example, we recently worked with a printer to perform the folding and gluing for a 56-page book consisting of 5 straight 4-page signatures; 3 accordion-folded/ glue tabbed 8-page signatures; and one accordion-folded/ glue-tabbed 12-pager.
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