Rickard Bindery is pleased to take this opportunity to answer a question from one of our customers. Pat from Quad Graphics recently asked about “running lightweight paper stocks for center spread forms and covers on saddle stitched books”. Also related to Pat’s question was how a minimum basis weight plays into the equation.
Today’s Helpful Hint topic, in response to this excellent question, is bindery heavy and quite specific. The following four tips will help ensure your next saddle stitched book is durable enough to withstand the product’s use without costly “over-engineering.”
The Heart of the Question
Why does this matter you may ask? Saddling stitching experts are often faced with the challenge of using light weight paper. Damage occurs when the stitches either puncture the light stock or simply split the paper at the fold. Here are some solutions.
Planning Matters
Whenever possible use a higher page count signature for covers or center spreads. Here’s why; signatures with either 4 or 8 pages have crisp, sharp folds. Whether done inline or offline the folding process tightly creases the paper’s fibers which can lead to problems on the binder. Conversely, layouts for a 16 or 32 page signature will end with final fold that is softer and less crisp than a simple 4 pager. This means less stress has been placed on the fibers, making the final product more durable. There are situations when a 4 page signature must be incorporated into the page count. In these situations, see if the 4 page signature can be sandwiched in between higher page count sigs. When dealing with self-cover books many of us have been trained to make 4 pagers either the inner or outer most signature but it certainly doesn’t need to be that way.
Grain Direction Matters
Everyone in printing knows the cover is king. Cracking, nicks, or blemishes on a cover can sink a project. It is wise to always be weary of grain direction. It is common place to take grain direction into account for thick stocks. However, lightweight stock selections should be given the same consideration, especially when durability is a concern. Design your saddle stitched projects so the grain direction of the cover runs parallel to the saddle stitches. Cross grain layouts are subject to both strength and appearance problems (i.e., cracking on the fold).
Weight Matters
The minimum basis weight for covers and center spreads is dependent on the project. The specifics regarding the final page count and overall size of the book in relation to what weight paper is under consideration will determine a reasonable minimum basis weight. For instance, a fly sheet outer cover would have a hard time surviving the wear and tear on a 64 page book made up of 100# enamel and measuring 8.5 x 11. Similarly, a light weight center spread will bear the brunt of the stitches as they punch through, grip, and clasp the meat of the book. As with so much that happens in the bindery, making a mock ups can prove invaluable.
Balance Design, Strength and Cost
Choosing the right cover stock is a balancing act. Often designers plan saddle stitched book projects without carefully considering spine strength requirements. For example, a thick book printed on 40# enamel paper using 40# as a cover will likely tear, even with the use of a soft fold for an outside signature. When in doubt, printer, designer and binder should all agree on stock selections during the initial planning of all saddle stitched projects. In today’s economy, every production dollar matters. However, we don’t want to cut any corners that compromise structural integrity.
One Last Note
Your friends at Rickard Bindery wish you very Happy Holidays! We look forward to working with you in 2009 and beyond!
The Rickard Advantage:
With five saddle stitching lines (up to 12 pockets) and a friendly team of planning and production experts, Rickard Bindery is available for project engineering assistance and on time deliveries of even the most challenging projects. Our saddle stitching capabilities include oversized and undersized stitching, loop stitching, Z-fold stitching designs and much more. Contact us anytime to discuss your project parameters and to put our experience to work for you.
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