FINISHING

Finishing is any process carried out after the job has been printed. It can be as simple as trimming a business
card or folding a letter to be inserted into an envelope or as complicated as case binding a book.
Below is a brief description of different finishing techniques and when they might be used.

Trimming

Most presses use paper slightly larger than the finished size to allow for register marks,
space for grippers etc and trimming is the process of cutting a document down to its finished
size by guillotine. Job specifications should include trim sizes as exact measurements of
the final product. If you want your graphics to go right to the edge of the finished page, you
must allow 3mm bleed.

Folding

Printed documents can be folded in a number of different ways. Paper of around 170gsm and above needs
to be creased to prevent it from ‘cracking’. This involves scoring the paper before it is folded. Text pages of
brochures and books are usually folded in 4 page, 8 page or 16 page sections.

More common folds (from top left): 6pp z-fold, 6pp roll fold, 8pp double parallel, 8pp z-fold, 8pp right angle (French), closed gatefold, gatefold, 8pp roll fold.

Perforation

Perforation makes it easier for the reader to remove part of a page or form. If the item is a letter that needs to
go through a laser printer for overprinting, request micro or laser perfs which are smaller and less bulky than
normal perfs.

Punching / Drilling

The process that puts holes in paper for binding is known as drilling or punching. If possible, include a copy of the binder as part of the print spec so that the sheets will fit. Holes in sheets that need to stand up to hard use can be reinforced with metal eyelets or a strip of plastic.

Numbering

This is a process that prints a unique number on a sheet and is generally used for tickets and business forms.
The process can be done on a litho machine as well as on a digital press.

Lamination

Lamination is the application of a thin sheet of clear plastic which is applied to one or both sides of a piece of paper, available in gloss, silk and matt finishes. It provides protection from handling and marking and overcomes cracking problems down the spine. Lamination is commonly used on the outer covers of prestigious brochures and corporate folders.

Encapsulation

Encapsulation covers and seals both sides of paper with tough plastic film, usually with plastic overlaps. Common uses for encapsulated sheets include maps, menus and ID badges.

Embossing / Debossing

Embossing is the process of creating a raised image or design in paper. Paper is pressed between two moulds, called a die, to permanently reshape the surface. The process can be used in conjunction with metallic foil or ink to produce a variety of effects. Embossing without ink or foil is called blind embossing and debossing produces a sunken image. The process tends to be used in stationery, presentation folders and covers for books and annual reports.

Foil blocking

Foil blocking is the process that stamps a design upon the cover. The design can be blocked in coloured inks, or metal foil, including special effects such as holographic.

Spot UV Varnish

For a dramatic effect, a spot UV varnish with a contrasting finish to the paper is instantly noticeable. UV varnishing can be applied overall or to an element of the design, the latter is known as spot UV. It is best applied over a laminate or onto coated paper as it may sink into uncoated materials.

Diecutting

Die-Cutting is the process of using a forme, a bit like a large pastry cutter to cut a shape into paper or board. Die cutting can make irregular shapes such as pocket flaps on presentation folders and shapes for promotional items (e.g. penholders etc).

Kiss cut

Labels are made by kiss cutting through the printed paper but not through the release paper on which the label is mounted. More complicated shapes can be cut by lasers instead of metal dies.

Padding

A pad is made from a stack of loose sheets. It is usually a very simple operation involving a brush and a pot of glue. A board backing can be used to strengthen pads and sometimes a cover can be attached using a cloth spine.

Tipping

When one sheet is glued to another sheet or to a folded section, it is referred to as tipping. Inserts, such as maps or special sections in magazines are often tipped into an adjacent section.

Glue Dots

Glue dots are a common way of sealing folded items ready to mail. It involves applying an adhesive circle or short strip of tape to the face of a booklet or self-mailer. It is relatively inexpensive and helps products go through the mail in good condition.

Perfect Binding

Perfect bound books are made by gathering folded sections which are then trimmed at the spine to get rid of the folds and expose the edge of each page. After the spine has been roughened and notched, hot melt glue is applied. When a cover is pressed against the glue, it adheres to the pad as well as forcing some glue between the sheets. After it has dried, the book is trimmed on the remaining three sides. Paperback books are perfect bound, so are most annual reports and technical manuals.

PUR Binding

The same process as perfect binding, but a synthetic adhesive (Polyurethane React) is used in place of conventional hot-melt glue. The glued spine is more pliable and the adhesive bond much stronger than a perfect bound product and so has increased longevity. It is more suitable for heavier weight stock, coated papers and digitally produced items.

Saddle Stitching

This is a method of binding where folded sections are inset and secured together with wire staples through the spine, allowing pages to nearly lie flat. Many brochures, catalogues, presentation folders and calendars are saddle stitched. The method is fast and inexpensive.
It is suitable for any product up to about 20 sheets (80 pages). How well the stitching holds depends on the weight of the paper and length of the staples.

Stab Stitching

This puts staples through the stack of sheets near the edge. This method gives a strong bind but means pages do not lie flat. Stacks of paper that have been side stitched can have a wraparound cover applied with glue.

Loop Stitching

This is a variant of saddle stitching where each staple has a small loop outside the crease to go over the rings of a binder. It is generally used for catalogues.

Spiral Binding

Spiral Binding is a process that binds a book with plastic or wires in spiral form inserted through holes punched along the edge. They allow the product to lie flat and to double over, useful for technical manuals, notebooks and calendars. However, they cannot have pages added to them and the spirals may get crushed.

Comb Bindings

Comb bindings are less subject to damage than spirals. Plastic combs come in a variety of colours and bend open to insert additional pages. They also have the greatest thickness capability of all mechanical bindings. However, they do not bend past the point of lying flat and as they are inserted by hand, are rather costly for large quantities.

Wire-O Binding

Wire-O binding is a continuous series of double wire loops run through punched slots along the binding side of a booklet. They allow the product to lie open doubled over, are durable, come in several colours and give a more finished look than spirals. However, additional
pages cannot be inserted and they have a maximum capacity of about 3cms. They are suitable for calendars, flip charts, reports and manuals.

Plastic Grip Bindings

Plastic grip bindings are suitable for relatively thin reports and presentations. Some styles are removable, others are permanent. Materials are inexpensive and easy to assemble.

Ring Bindings

Ring binders come with solid or padded covers, pockets inside or out, a variety of ring shapes, sizes and configurations. The most common configurations are available off the shelf, whereas more unusual configurations can be made to order.

Case binding

Case binding begins by sewing folded sections along the spine which are then gathered and trimmed on three sides. The stack is put inside a case made of binders board covered with paper, cloth, plastic or leather. The case, which can either be round or square backed,
is held to the sections by glue along the spine and between end sheets.

Selective binding

Regardless of what binding method you choose, you can bind versions of a product for specific audiences, depending on variables in a database. For example, you could have one version of an educational prospectus for science students and another for those interested in arts. Machines capable of selective binding link your database to the binding lines. A computer reading your database instructs the machine to skip or add a folded section or apply a different version of a cover. Effective use of selective binding begins with planning and design and can help reduce costs (by reducing waste and postage) and speed up production.

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