Book Production From Start To Finish, Digital Printing and Binding Perfect

welcome back today i’m going to talk about how i perfect buying books uh there’s a lot to talk about between the different types of perfect binding available papers lamination there’s all kinds of stuff to talk about i am it’s going to be kind of all over the place because i’m not necessarily filming this in the order of the process i’m just filming this conveniently for me so before we can even start printing we need to actually design a book and a cover on a computer and there’s there’s better ways and worse ways to do that i mean if you’re going to have bleed you need to include bleed on the cover and text of an eighth of an inch um let me show you how i make covers really quickly oh yeah and we use adobe software for everything basically in pre-press and in the creative side of things if we have a vector image that we need to manipulate that’s going to be done in illustrator if we have raster images that we need to work on that’s going to be done in photoshop and then we’re going to take those along with text and bring them into indesign and create the actual files of the cover and book and then from there we output a pdf and send that to the press and for those of you who don’t know a raster image is a photograph basically an image that is made up of lots of very small dots and uh when you zoom into that it gets blurry whereas a vector image

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is uh you know like a font that is made up from points and lines and it doesn’t matter how big or how little that is it’s still going to be crystal clear so that’s that’s the difference between those two okay so we have our indesign open and if we do command n it’s going to open up a new document for us so uh if we just do you know a typical letter-sized cover actually okay so if we have an eight and a half by eleven book and we need a cover for it the cover needs to be 11 by 17 and then plus the spine to calculate the spine what you’re going to need to do is well for a 60 pound paper you take the total page count so let’s say there’s 234 pages you divide that by 435 and that’s going to give you 0.537 so let’s round up to 0.54 and that is going to be the thickness of the spine and what i do to quickly put the spine in there is i make this a two column document and you go ahead and put 0.54 as the gutter that’s going to show up in the center gutter the orientation needs to be landscape uh i do include bleed on all my covers whether or not i need it or not and you’ll see why in a second i don’t use any slug so we go ahead and create that so right there we have the cover this is the spine that’s that i put in there so that’s automatically set up and centered there so 0.54 and here’s your front cover and there’s your back cover here uh and then the other thing that i do for every cover is you i just draw a little box here and it’s going to be 0.54 and i just drag that up so it’s within the bleed so that line right there is going to show up on the printed covers and that just helps out with who who’s ever binding them to locate the spine most books you can easily locate the spine but sometimes it’s a little trickier and this is just makes it completely easy to figure that out so then once you design your cover you export it as a pdf command e is export and you can also go up here to file export we’ll just put it out on the desktop here you want to set this to adobe pdf print save you’re going to open up a second one i always do press quality but then you have to go down in here and make sure that your crop and bleed is included because that’s some information that you’re gonna want and then you can open up the cover here and acrobat and see what it would look like now i didn’t design anything on here but you can see that my spine mark is in there you’d have your front cover your back cover your spine your bleed your crops it’s all good to go and you just send that to press now if you’re doing a the the interior pages or what i like to call the guts of an eight and a half by eleven book uh you’d make this eight and a half by eleven the orientation would be portrait uh click facing pages and that’s gonna put your fit your pages side by side so you can see the left and right the left hand pages are always going to be an even number and the right hand pages should always be an odd number let’s see here so let’s just make this uh oops 124 pages i forget what i said i made the spine to be but anyways it’s one column the gutter setting isn’t going to matter here as far as margins go for a book

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it’s really personal preference but i strongly recommend that the inside margin has more margin than the top outside and bottom and that’s just to keep your text out of the gutter so let’s add an extra quarter inch on the inside actually let’s do a quarter inch all the way and do an inch on the inside i would say at minimum you’d want an eighth of an inch more on your gutter it’s up to you whether or not you want to have bleed if you’re going to include bleed so let’s create that so here’s our book then zoom out here so you can see that the inside gutter here has just a little bit more it has that extra quarter of an inch and that’s so your text doesn’t get lost in the center here when this is perfect bound you’re going to lose a little bit of that so you want to keep everything out a little bit more but this sets your your book up so you have left and right pages i could go into a lot more detail here as far as you know insert a marker of a page marker but actually i mean an indesign tutorial you can already look up on youtube so okay once we make a pdf i transfer it over to this pc here because that’s where my imposition is so i open up an acrobat and i use a program called pdf snake to impose unfortunately i heard that’s no longer available but it’s great so i have presets in here this is an eight and a half by 11 and we’re printing it two up on eleven a quarter by seventeen and a half i hit ok it’ll impose that two up with an eighth of an inch trim on the top and a quarter inch gutter and a quarter inch over on this side so this sheet just needs to get cut in half before it goes into the perfect binder uh first paid the last page it’s all good to go and then i just go to print and i send it to the konica 1200 and again in there if i hit properties i have preset right there two up short grain i just load that up hit okay and print it okay so i started printing these covers on the 1070 here this cover is getting printed on a 12 point c1s paper now that means that it is coated on one side and not the other side i use a tango digital 12 point c1s it’s 235 gsm and they’re 1913 that means the grain direction is in the short direction here and that’s to help it fold around the book and reduce any type of cracking that would happen at the spine so this is coated on the front side it has a gloss coating on this side and the back side is uncoated the uncoated side is uncoated because uncoated paper will absorb adhesive easier than a coated sheet now the adhesive i use is specially formulated for a gloss or uncoated paper so it doesn’t really matter but basically all the perfect line books i do i use a c1s paper one of the reason that i use a 12 point instead of a 10 point is because it just creates a little more body to the cover it’s thicker just a little more durable downside is it’s just slightly more expensive and the 12 point is also prone to curling a little quicker than a lightweight a lighter weight 10 point but i use 12 point for all my covers so we could bind this cover onto the book as is without any type of coating on top it’s going to create more of a matte looking book cover it’s a little bit cheaper the downsize is you lose the durability of a gloss laminate and i laminate uh most of my covers it just depends what the customer is gonna want but a gloss laminate will make it glossy and make it durable it’s a little bit more expensive than a uv coating but a uv coating doesn’t last near as long man that stuff stinks so i do lamination for pretty much all my covers so most books uh even 6×9 and some large five and a half by eight and a half books i will print one up on that 13 by 19. if for some reason i can fit two up i do do that as well uh i have a 13 19 grain long paper here for that alrighty covers are finished now we’re going to use uh the dnk laminator to laminate i use a 1.5 mil film it’s 12 and a half inches wide by 6 000 feet when i put it on here and it covers the whole sheet except for a quarter inch on either side and that allows the knife to come through here and cut as far as if you’re interested in what pressure settings i’m using here i have 50 pounds of pressure uh on the nip rollers here that squeeze it then i put 45 pounds on the pool roller which is back here and pulls it through and the mandrel break and turnaround roller i run as little as i can because i don’t want to if you if you turn the brake on which is right here what you’re going to do is create tension and that’s going to really curl your paper you want to laminate it as relaxed as possible so that it lays flat and we’re running at 250 degrees fahrenheit i put two scrap pieces on the bottom because they stay in the machine after all the laminating is finished so we’re all up to temp load it up uh all we need to do is comb the feeder and move it up then turn our air on we need to disengage the drive and then jog it forward to the sheet that’s in there once it gets there we engage the drive close the nip start the laminator turn the knife on and we’re off to the races i also forgot to mention you need to put in the sheet length that’s the length from the front to the back and all that does is tell the knife when to go across it’s all timed out so that when the seam comes up the knife comes across and cuts so everything looks good we can speed this up quite a bit i usually don’t go too terribly fast just because i’m not really in that much of a hurry it runs by itself so just briefly how this works is it takes the film uh and the adhesive side is out this roller here is heated and is pressed down on the paper then it comes through here this roller right here is a de-curler roller and then it decurls it and then right here it’s cut apart and then they’re done and you want your cover to be pretty flat when it comes out i like to give it a little bit of a down curl so then when it becomes acclimated to the temperature and the humidity um then it’ll straighten out a little bit [Music] i also forgot to mention this is super stick film meaning that it’s specially made the adhesive is extra aggressive for toner-based printing okay once i have it sent back here it’s real easy we just recall i sent it the folder two in here it’s gonna be the last file we just print a hundred of them and we’re good so this is getting printed on eleven and a quarter by seventeen and a half seventy pound it’s a short grain that’s about all there is to to printing uh the guts of the book i’ll talk a little bit more about paper and cutting that down in a bit so this press will print to the edge of the sheet you can see our crop marks here these will all get cut in half once and then that’ll let trim on three sides there and three sides here this all looks good whenever i print out the first book i make sure that it’s the right file is make sure that all the corrections are made that needs to be made and also look for issues that are either coming from the press uh unwanted lines or artifact print quality problems but also problems that could happen in the rip where you have transparencies and screens getting applied where they shouldn’t so i like to take a good bit of time and go through it and just make sure it is visually as good as it gets so again this is 70 pound text it is 17 and a half by 22 and a half and the grain direction is long i’m going to cut it directly in half it’s going to become a short grain sheet and that’s what we’re going to print on it’s williamsburg if you’re interested in that it runs real nice i have no problems at all running this stuff and my my trimming is designed specifically i know it’s kind of an odd sheet size to run 11 and a quarter by 17 and a half through your press you have to set it up as a custom sheet but it saves a ton of time because you’re just going to cut all these once and then all the final trimming gets done by a machine it just minimizes the amount of cuts and if you save time you save money it’s all about efficiency there’s so much room for activities here now typically this is right up here and i stack books on here to be bound and then bind them i’m waiting for cover material for these books so that’s kind of handy about this it’s on wheels i can just move it out of the way and keep moving on the other books since i have covers for them done ready to roll and it’s nice i can just stack my books here and bind them so let’s trim some books down and i’ll show you how i perfect bind [Music] next we need to get our covers ready for binding so every single cover that i bind has a 1 8 inch overlap beyond the edge of the text book block on this book we have an eighth of an inch uh between the trim and the edge of the sheet and i want an additional eighth of an inch from the book cover so that means from the trim on the top i need an extra quarter of an inch and an extra quarter of inch on the bottom and that is going to align that crop mark directly with the crop mark of the text and i usually just take a a pencil and mark it so it’s a good idea to put a magnetic pad on there whenever you’re cutting anything that is gloss laminated not extremely necessary but it’s just a good precaution [Music] now this is a cp board 3002 perfect binder uh it’s the old perfect binder i had was a 3001 a little bit more manual but this is a great machine and it’s fabulous because it’s in line with the three knife trimmer for many years i we trimmed down by going back to the guillotine and manually trimming the three sides of the book it’s a great way to get started with a very low entry piece of equipment but as you grow this literally cuts the time in half because after you drop it the book block into the binder the next time you touch the book it’s done and ready to be boxed up and sent out the door it’s a huge time saver okay it’s telling me that the waste bin is full so before we get started i gotta empty these out real simple uh the back one will fill up quicker because pretty much all my trims are a quarter inch on the back and an eighth on the top and bottom but each side has the trim which is the side of a book as it comes through here setup is super simple uh what we have to do is go in here to job we’re doing an eight and a half by eleven book press enter and send then we’re done this right here is actually a cooling tower and it gives the adhesive just i don’t know if it takes a minute until it gets to the top of that just for that adhesive to cure a little bit more and and become more solid so that’s the cooling tower i forgot to mention that this is a challenge cmt 330 three knife trimmer challenge makes some good stuff so let’s take a look inside here and just break the different parts down right here is the book carriage and we’ll take our unbound book block and put it in there there’s a vibrating table on the bottom that jogs all the paper brings it all to the bottom it will then clamp it’ll go past the nipping knives here and there there are notching knives there’s one right here that they will put notches in the whole book spine and that allows the adhesive to get absorbed up in there and create a stronger spine of the book then we have the glue pot here that applies glue and then over here is the cover nipping uh covers get piled up here get pulled in uh they’ll get scored there’s a scoring mechanism here that will provide the hinge score and also a score on the spine if you’re doing book flaps you can score that as well there’s pressure from the bottom and pressure from the sides that gets applied and we can change all of that in the settings here the amount of pressure the amount of glue the amount of vibrating the amount of [Music] cut that the nipping knives take and then the length of time that it holds the book before it drops it so then it’ll drop it out and it’ll go through the three knife trimmer there’s adjustments here and this adjusts the skew of the book cover and also the lateral movement left and right here of the book cover since i always keep an eighth of an inch and i make sure it’s trimmed down correctly basically never have to adjust this uh so i just load covers and uh set up the length of the cover right here so this number here is the length of the sheet which it’s a 13 19 sheet and then this number right here is the length from the spine to the edge of the sheet so those are the only two numbers that we need to put in there and our first book should be sellable so that’s pretty good i just wanted to pull the cover down a little bit more and we’ll get this to crimp in a little bit tighter [Music] but the alignment’s good the amount of glue is good it’s not too much not too little so let’s uh do a couple of small adjustments here okay so i want to move the cover back just a little bit [Music] and increase the side pressure and i think it should be good [Music] that’s pretty good that’s lined right up let’s keep it moving so this is the the adhesive that i use it’s called techno melt adhesive uh it comes in a pellet form and then uh just melts in here i think it’s that uh what am i melting that at i have it set at 284 degrees fahrenheit that’s called an eva hot melt glue there’s actually multiple ways you could do a perfect bound book you have eva hot melt like i have here or you could do a pur polyurethane reactive or you could do a combination of that and a sewn book which will lay a lot flatter where the signatures are actually sewn together and then glued so there’s plenty of options out there the most commonly used one is probably eva hot melt uh the pur is a little bit uh more durable and will just stick to gloss papers a lot easier uh it takes longer for that to cure there’s a bunch of pros and cons between the two i don’t know that i’m educated enough to actually deliver that to you at this point but ebay hot melt works great for me you can adjust the amount of grind if there were signatures and you wanted to grind off the bottom of them uh i typically run it at .02 i just feel like it it creates a little bit more of a roughness i do need to go in there and measure my notching blades and make sure they’re sharp too i haven’t done that in a little while i also didn’t mention this you can adjust where your nipping your side nip comes in to one side or the other and then you can adjust glue film this also has a side glue that will apply glue on the edge of the book block i rarely use that though i don’t really like it i think that’s just a personal preference and you can also adjust the speed so right now it’s on turtle mode and you can see like this is the bottom of the book block after it gets milled it slowly moves it across so there’s a lot more grooves and it slows your machine down which is a bummer but it will produce a stronger bind there’s more adhesive in there but you could change that to rabbet mode and it goes quickly across and there’s just less grinds i might play with that one way or the other [Music] what other adjustments you can you can change the orientation like right now i’m binding it so the books come out with the cover side up you know you could change it so that it comes out with a back cover up i tend to do it this way just because if there were any mark marks created by the conveyor system it would be on the back cover not the front cover so when the binder set up and ready to run uh i hit this three times and what that does it’ll automatically start feeding the next cover uh before i put a book in that speeds it up so you can see there’s already a cover in there that’s ready to go the nice thing too about this machine is there’s a book per hour meter here that changes as you’re running uh usually i can expect between two to three hundred books an hour when it’s running but trust me there’s much faster larger machines out there that are gonna do you know three to five thousand an hour so this is just a little baby well i gotta quit messing around and get back to work got a lot of books to bind here i guarantee you i missed things i’m sorry i just kind of went as i go here so if you have questions make sure you leave those below in the comments or if you’re watching this and you have a little bit of wisdom that you’d like to share with everybody else make sure you leave that down there as well thanks for watching thanks for subscribing don’t forget to give it a thumbs up we’ll catch you on the next one [Music] you