As print shifts from offset to digital, and run lengths shrink to reduce inventories, a whole new generation of perfect binders has been introduced. These machines are built for short- and medium-runs, and can quickly adjust to changes in both the book block and cover sizes.
You can set up a short-run, hard-cover module that can produce a few thousand books a day without making a million-dollar (or more!) investment. So don't routinely send the work out if you've got it. Looking at the options for bringing it in-house can add to your cash flow and improve your bottom line.
The last major milestone in adhesive binding was the introduction of PUR (polyurethane reactive) glue, which cured by forming a chemical bond with paper. But a newer adhesive system may be about to make a debut.
There are lots of additional techniques that can be used to enhance the PUR process. One new technique is a plasma-discharge station (similar to the electrical corona discharge used to treat many flexible films). This is thought to change the surface tension and polarity of the book block, enhancing the bind strength.
In the ’50s, the race began to automate book binding, with firms vying to produce complete, automated systems that could turn out 50-60 hardcover books per minute. The new production model is a smaller work cell requiring a single operator.
Bindery system manufacturers have faced a few tough sales years of late. This has spawned a lot of brainstorming about how to generate revenue. One manufacturer has come up with a program to give older machines a complete “makeover.”
Even though I didn’t get the opportunity to visit all of the finishing system exhibitors at GRAPH EXPO 2012, I did see enough to form some opinions on current trends and developments in the industry. While digital printing was once again the central focus of the show floor, finishing remains key in creating quality, exciting products across the board.
Mechanical binding remains the most practical finishing method for a wide variety of products, which benefit from the “lay open” quality of the process. Newer, larger machines have been introduced that combine the collating, inserting, punching and binding operations into one process.
In the past year, I've had to get up close and personal with hardcover binding and my horizons have been greatly stretched as to what can be turned out in the finishing department. The latest electronic devices even offer opportunities for traditional finishing.
Color digital printers now realize that they can produce the complete product in-house, including high-quality hard cover books. The new workflow can produce one or two unique books at a time, where it’s necessary to change sizes rapidly.