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If you want to pack a powerful revenue punch in a small size, consider the market for small format/miniature folded products. As printers in this coveted niche know, it’s not atypical for products worth tens of thousands of dollars to be shipped on a single skid. Today, we’re going to focus on the general commercial portion of this lucrative business. Next month, we’ll cover the other side: pharmaceutical.
NOTE: Since the distinction between small format and miniature folding is arbitrary and relatively insignificant, we’re going to simplify matters and refer to this class of folded product as “small format.”
What is Small Format Folding?
Small format folded products are too small for normal folding equipment with standard folder rollers (1 ½” diameter). Small format machines have smaller folder rollers, which allow smaller panel sizes, down to 7/16”. As a general rule of thumb, any product that finishes with at least one dimension less than 2” places it into the realm of small format folding.
Small format folding is a specialty product because it:
- Requires different folding equipment
- Prioritizes machine operator finger dexterity over strength
- Is subject to significant stock restrictions
- Requires careful packing consideration.
Typical Product Applications
If you or your organization is looking to print general commercial small format projects, look for work in the following areas:
- Coupons. Coupons frequently are printed on enamel stocks, some of which can be as thick as 10pt or more.
- Hang Tags & Neckers: Frequently printed on enamel stocks, with an extremely wide range of stock selections.
- Instruction, warranty and product information sheets. These are printed on offset stock, usually in the 40# and 60# range.
- Point-of-purchase promotions. These promotions are alluring and often affixed onto a package, into a bubble pack or string-tied directly onto the product itself.
Although there’s a perception that small format folding is a niche specialty, the process of putting ink on paper shouldn’t be too challenging. Paper weight, ink colors, registration issues and paper sizes should all be within the “normal” range. Creating a symbiotic relationship with a small format finisher is usually the higher hurdle. General commercial small format work is open to competent printers of any stripe. (As we’ll see next month, this isn’t the case in pharmaceutical small format folding primarily because of true pharmaceutical printing is done on lightweight stock, usually between 27# and 33#.)
The Big Two
If you’re new to the process of bidding on and producing general commercial small format folding, make sure you know the answer to these two questions:
Does it lay flat?
This is critical because if the piece is to be automatically applied into or onto another product, then it must be flat in order for the machinery to handle it easily. When this becomes necessary, either glue or a lay-flat folding technique is required. Unlike normal sized folding projects where glue heads can usually be added with minimal forethought, assuming anything about glue in the small format world is unwise. In most cases, adding glue requires the folder’s rollers to be cut because this hollowed out space will allow for the glue to pass through the folder with out smearing. Unfortunately, once the roller is cut to allow for glue, their may not be enough “meat” on the piece left for the remaining roller to grip and make the fold. No grip – no go. Therefore, whenever glue is required, involve your finisher early in the planning process. Recognize that some small format folding companies have developed a “near” lie flat folding solution that doesn’t require glue.
How is it packed?
In the small format folding world, getting packing instructions right is critically important. Many small format folded products must to be automatically fed into high speed insert and onsert machines and project planning mistakes can be extremely costly. Packing options for small format general commercial work include:
- Rubber band packed convenient (fastest and least costly)
- Row packed with chipboard dividers (mid range packing option)
- Tray packed (highest quality, most flexible for automatic feeding)
Advantages of Outsourcing
Some printers shy away from pursuing work that requires large amounts of outsourced finishing. However, it’s difficult to be all things to all customers. Contracting small format folding work to qualified finishing partners means you get access to their machines and core competency expertise. Small format work travels well because it is easy to pack and inexpensive to ship. For example, the cost of shipping a skid of work is minimal considering that the high value of small format printed and finished work.
If you’re a printer and take time to familiarize yourself with printing and finishing small format folded work, you will cast a wider net of services and increase your relevance in the marketplace.
The Rickard Bindery Advantage
With 107 years of post press experience, Rickard Bindery is the right choice for your next small format general commercial folded project. Our advantage for you includes:
- A fleet nearly two dozen small format and miniature folding machines
- The ability to fold panels as small as 7/16-inch.
- Multiple glue heads compatible with small format folding machinery
- A convenient, centralized location in Chicago, Illinois
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