This project was a challenge from the perspective of providing a solution.  The customer had originally sent this job to another bindery.  But it was a very labor intensive project and the other bindery could not meet the delivery requirements.  The job was in-process (some of the work had been started) and had to be re-packed and shipped to Pacific Bindery Services (PBS).  The time invested in production coordination of this job was three times what would normally be required: as incoming product had to be re-sorted, inspected and then sent to the appropriate department for finishing and binding.  Our significant issue was to coordinate the job so that the pages pre-done by the other bindery were labeled and sequenced correctly and that we could integrate the pages into one cohesive book.

This job’s critical components were in achieving the cross-overs on the short and staggered sheets.  Line-ups and cross-overs were critical for the customer:  they were promoting multiple paper types with one image and carrying that image across a number of short, staggered sheets.

Cutting, collating and punching had to be done with precision to achieve the end customer’s design.  When the job arrived, parts of it were in various stages (some sheets had been cut, some folded, some punched) of in-process work.  But the majority (more than 80%) was incomplete.

Cut, fold, punch, trim, collate and semi-hidden wire-o® bind 21,000 books (our portion of the job). 6 x 9.  52 pp plus Wrap Cover.  Shrink wrap in 5s and pack 50 books per box.

5 sheets staggered, starting with 3 x 9 in ½” increments to 5 x 9.  7 sheets staggered starting with 2 ½ x 9 in ½” increments to 5 x 9.  1 short sheet 3 ½ x 9.  1 short sheet 2 7/8 x 9.  12 full sized sheets at 5 ½ x 9.  Inside text pages average 10 pt. (ranging from 9 pt to 12 pt).  Covers were manually punched; inside text pages were automatically punched.  Some of the short and staggered sheets were supplied pre-cut (not all) and were trimmed to size after punching.  18 sheets collated on the gatherer; remaining 8 short and staggered sheets hand collated in order, straight up and married together with cover.  Jogged carefully to spine and offset stacked for wire-o®.

Typically binderies do not want to do continuation-type of in-process work from other binderies.  If there is a problem, who holds the responsibility?  We agreed to take on this project to help our customer.  The time investment in the upfront material organization paid off and allowed us to complete the job on schedule and done right.  And they said it couldn’t be done!

Semi-hidden wire-o®  with ribbon book mark. 1200 books.  9 ½ x 10.  Thick book (1 ¼” thick) with double thick cover (22 pt x 2) and heavyweight index tabs (22 pt).  Flysheet plus 242 pps, plus 5 tabs and wrap cover.  Collate marry, punch and semi-hidden wire-o®.  Cover and index tabs overhang text pages. Single flysheet (Translucent).

The challenge on this project was in the punching and wire-o of this thick book and the heavy weight/heavy thickness of the paper stock. The process is:  punch the double-thick wrap cover (concern about ‘tearing’ through the double thick cover but we were able to minimize) manually for control.  Hand-collate and punch the fly sheet and 5 tabs. Collate and punch the 242 pps (6 pick ups). Marry into one book and wire-o.

Cut, gather, PUR perfect bind and trim 32pp + 5 flush foldouts + cover 3000 books. This is a beautiful predevelopment piece for an upscale Madison Avenue Condo located on 66^th St. in New York. Each floor of the building only has three suites, therefore, five flush foldouts were made as a part of the design to show the three floor plans and to showcase the key shopping area in Madison Avenue.

The difficult part of this booklet is in the binding of the five flush foldouts. Since the foldouts were full sized and flush at face, they were supplied to us pre-folded to final size for our binder. When gathering the signatures, we had a team of handwork specialists pre-gather all the pages and then hand-feed the signatures into the binder. This ensures the highest quality binding because we control the pages and sheets that go into the book and minimize wastage. The design of the book includes images and text that crossover from one page to another. As you can see from the samples we’ve provided, the crossovers from one page to the next are perfectly lined up. This gives the book a seamless look throughout. Because the crossovers were folded and bound so beautifully, if there weren’t the small triangular corners cut out, you would not have known there was a foldout flap.

Cut, fold, gather, stitch, and trim 44pp + 6pp cover 5000 books. Then refold inside back cover to form as inside front cover with a gusset. This piece was designed with functionality in mind as there are a number of design features that help the user use this piece effectively. For example, there are coloured tabs throughout the book that line up with the coloured panels on the inside of the back panel. This acts as a Table of Contents when the extra panel is folded out in opposed to a traditional Table of Contents in the front of a book. Aside from being colour-coordinated, the bindery work for this book requires critical lineups and cross-overs for the Table of Contents to work effectively.

From a binding perspective, this job was a challenge to make as there are full size foldouts located in the middle of the book. Folding the signatures before saddle stitching required great attention to detail as the sheets all had to fold to the same size at the face. These foldouts were flush at face meaning we are not able to take a face trim to the book after saddle stitching. In order to achieve this, the book was created in two passes. During the first pass, the five flush foldout signatures were pre-gathered on the stitcher. During the second pass, these pre-gathered signatures are hand-fed into the stitcher at the centre of the book which then adds two additional four-page signatures fed from pockets before gathering the cover with the rest of the book.

After the book is finished stitching, a team of handwork specialists carefully folds out the inside back cover, forms a gusset, and folds it over the inside pages and becomes the inside front cover.

We entered six pieces into the Product of Excellence Awards this year and won four awards in the competition. They included two Best of Categories (one for Stitching and one for Adhesive Binding), one Certificate of Merit in the Mechanical Binding category and one Certificate of Merit in the “They Said It Couldn’t Be Done!” category.

While we take great pride in the quality of work we do, we could not win international awards year after year (more than 30 in the last seven years – but who’s counting!), without the opportunities that our customers provide to us – you give us exceptional work to bind and finish. Thank you.

All of the work we do is important to us and, of course, to you – we strive for perfection and continuous improvement in every job. We are proud to receive this recognition from our peers and we are proud that it reflects so well on the commitment and the skills of our employees. We share these awards with you!

Most of our staff are long-term employees and all are well trained and experienced in bindery and finishing. In addition to on-the-job training, all employees have the opportunity to gain additional knowledge – whether it’s through certified in-house training or through local industry technical programs.

For more information: 1-888-873-4291 or e-mail info@pacificbindery.com or k.bovay@pacificbindery.com.

Next week: We will showcase one of our four award pieces.