Perfect Binding: The Art of Making Paperback Books

Perfect binding might be the most common method of book binding in 2023. It has many advantages over case binding or mechanical binding with coil or wire. Paperback books are the ultimate compromise between cost and quality. A perfect bound book is ideal for taking on the go, unlike a bulky case bound book. Market readers seem to absolutely love buying perfect bound books at the lower production cost.

Books are as old as printing. One of the first things done with the printed sheet was to bind them together into a collection. Books serve as essential tools, with every feature crafted to enhance the content they hold. Their purpose is reading, and as we create them, our duty is to ensure their durability, readability, and correct construction.

Book binding, a centuries-old art form, has stood the test of time. Over the years, bookbinding has evolved to incorporate modern technology and techniques to meet the growing demand for high-quality books. Automation has allowed us to manufacture more books than we could have ever imagined.

Of all types of books the perfect bound book is a classic. Consumers usually refer to a perfect bound book as a paperback book. Perfect binding is the name of the manufacturing process to make one of these books. While sometimes referred to as thermal binding, we will use the term ‘perfect binding’ for the purpose of this article.

A perfect binder is a book manufacturing machine that makes paperback books. Perfect binding involves gluing single sheets together at the spine and wrapping them with a soft paper cover. Consumers call them paperback books but in the industry we call them perfect bound books.

Unlike traditional binding methods such as saddle stitching or spiral binding, perfect binding has a square spine with sharp corners. You often see the printed spine of the book when you store it on a bookshelf. Perfect binding machines come in two main styles. The difference is in the types of book binding glue that they use. Two major types of binding glue exist. Machines designed for book binding are unique to the type of glue they use.

Not all perfect bound books remain as paperback books. We typically start casebound books as perfect bound books before adhering the hard cover to a casing. Hard cover and case bound books require perfect binding. Books are bound with a case cover instead of a finish cover. Later that casing is used to adhere the hard cover to the rest of the book.

The importance of perfect binders in the bookbinding industry cannot be overstated. These machines enable publishers and printers to produce high-quality books quickly, efficiently, and cost-effectively. Moreover, they’re ideal for printing small quantities since they can set up for book-of-one production. Older binders would require large amounts of set up books to be wasted while tuning the machine. Modern book binders make a perfect book the first time and set up in mere seconds.

Perfect binding, thanks to its strong bonding quality, can accommodate various paper stocks. Typical ranges are from about 60 gsm to 300 gsm thick cardstock or even heavier paper. PUR binders work well even with thinner papers that have less surface area. This makes it cost-effective while still ensuring quality output. Companies can produce different books like catalogs and magazines, reports and brochures more easily by using automated binders. Perfect binders are an integral part of the bookbinding industry. They enable publishers to produce high-quality books at a low cost.

One massive advantage of perfect bound books is that they stack very nicely for shipping. The transportation costs associated with delivering book orders can get prohibitively expensive. Being able to fit more books in a box can mean a huge amount of savings during the delivery phase.

Trimming is the final step of perfect binding production. Book trimmers are specialty machines that are designed specifically for trimming books. Books can be trimmed on a regular guillotine cutter but it is hard on paper cutters and tricky because the operator needs to manage the shear direction to protect the book spine. Book trimmers are a category on their own but generally speaking there are single knife trimmers that spin the book and there are true three knife trimmers that are much bigger and much faster.

Perfect binding is a popular book binding method that uses adhesive material to bind the pages of a book together. The perfect binding process has become more sophisticated over time, as advances in technology and materials have led to the development of two main types of perfect binders: hot melt EVA perfect binders and PUR perfect binders. Some machines are also convertible and can use both types of glue.

• PUR Perfect Binders
• EVA Perfect Binders
• Convertible Binders

EVA perfect binders are the classic style of book binder that has been used traditionally. These machines have a simple heated tank and use a basic hot-melt glue that becomes soft at temperature. EVA glue works well but has some minor drawbacks such as poor performance in extreme temperatures. 

PUR perfect binders are designed to use PUR glue. PUR is poly-urethane resin and it is a very durable plastic. It is the same material used in bowling balls and soccer cleats. This material is a one-time melt and makes a very high quality book. 

The major benefit when it comes to book binding glue is adherence. PUR glue chemically bonds to water molecules within the paper itself, whereas EVA makes a more mechanical bond by intermingling with paper fibers. This chemical bond allows operators to use smooth coated papers without worry of the book falling apart. PUR is also described as a one-time-melt and holds up better in extreme temperatures. The glue is more flexible meaning books will lay flatter, creating a better experience for the reader. Additionally, PUR glues are more forgiving when it comes time to recycle. Certain properties make it easier for recycling facilities to extract glue from paper pulp.

The disadvantage of PUR is a slightly higher cost of production, mostly related to the need for additional hardware. PUR systems need Teflon coated tanks, complex extrusion application systems and usually a sealed pre-melter to keep oxygen from setting the glue prematurely. Fortunately these additional costs are mostly within the initial investment and once the hardware is in place, the cost of operation is very close to that of an EVA based workflow.

PUR glue typically requires a 24-48 curing time before the book can be opened. Many manufacturers use their shipping time as curing time but there can be situations where the added wait for curing can slow production.

Hot melt EVA stands as the most commonly used adhesive family in the bookbinding industry.EVA perfec binders uses EVA glue. EVA, a thermoplastic compound, is heated and applied to the spine edge of each sheet before we clamp them together into a book block.

The machine warms the EVA glue pellets, then dispenses them onto the spine edge of each sheet before clamping them together with a book spine. EVA machines are very simple. Operators just add more pellets as they use glue. They can simply turn off the machine at the end of the day and remelt the same glue tomorrow.

Cost is the primary advantage. EVA binders and EVA glue are less expensive. The next major advantage of hot melt binding is its fast drying time, allowing for quicker production times compared to other methods like PUR binding. It also creates strong adhesion which results in a sturdy book cover and spine assembly. On the downside, hot melt binding may not be ideal for larger books or those with coated glossy pages since it may not provide enough strength or durability for long-term use. EVA also softens in extreme heat and can become brittle in extreme cold.

Polyurethane Resin (PUR) offers superior bonding strength compared to traditional EVA glues, making it ideal for more demanding applications such as photo books or those with coated or glossy pages. Basically, PUR perfect glue binders work the same as EVA binders with some key differences. The primary difference is that the glue tank in a PUR binder is teflon coated. This lets the glue be removed which is required at the end of every production run; unlike EVA which can be remelted the next day. PUR must be removed and only cured one time.

The main advantage of PUR binding is its superior strength and durability, making it perfect for high-end books that require long-term use. It can also be used on a wider range of paper stocks and other materials such as plastics or laminates. However, due to its reactive nature, PUR glue requires more time to cure, leading to slower production times compared to hot melt binding methods.

Additionally, PUR binders tend to be more expensive than their hot melt counterparts due to the advanced technology and specialized materials used. In summary, both hot melt and PUR perfect binders offer unique advantages and disadvantages. Bookbinders and publishers must carefully weigh factors such as book size, paper stock quality, required production speeds, and budget constraints before deciding on the perfect binder type that best suits their needs.

As discussed in the previous section it is important to decide if EVA or PUR glue is best for your application. The glue type is usually the main driving decision of what binder to buy. PUR binders will almost always have a separate side glue tank and EVA binders may or may not.

Side glue is another consideration. Side glue is for the face and back of the book to hold the front and rear cover closed. The side glue is usually applied in a thin strip that is protected by the hinge score. Side glue is usually pressure sealing adhesive whether the spine glue is EVA or PUR. Side glue stays tacky, so if you pull off a cover, it reattaches, keeping the book intact.

One of the most significant factors to consider when choosing a perfect binder is the size and thickness of the book. Different types of perfect binders are designed to handle various book sizes. You simply don’t want to get a binder that won’t make the books you need. Making sure the binder can make your book sizes is a primary consideration.

Thickness is something to watch. Some hot melt perfect binders can handle books with up to 2 inches spine thickness, while others can only accommodate books with a spine thickness of up to 1 inch. It is essential first to determine the size and thickness of your books before selecting a suitable perfect binder.

Some of the higher end book binders have built in scoring. Scoring wheels will put a score into the sheet where the corners of the book will be. This helps to create a high quality finished book that has corner and hinge scores in the perfect position. Machines without built-in scoring are less expensive, but for the best-looking cover, scoring might be necessary. You can always score before binding, but having an automatic, built-in feature offers much more convenience.

When selecting a perfect binder, a major factor to consider is production speed. Depending on your production needs, you may require a high-speed binding machine such as a 4-clamp or a carousel with up to 9 book clamps. For many operations a single clamp book binder is enough but they are slower. Be mindful of comparing carriage cycle time to book production speed because some manufacturers play tricks when specifying their machine’s true speed.

For high-volume applications such as book publishing companies, book binders with multiple clamps are the best choice. This style of binder will produce many more books in the same period of time.Properly staging the work is one of the most crucial factors for maximizing the speed of your binder. Having carts with book blocks and book covers within arm’s reach greatly helps. If you stack the book blocks offset, a binder operator can run at nearly twice the speed.

The quality of binding required dictates which type of glue system will best suit your application. PUR glue offers excellent adhesive strength performance across various substrates and is highly resistant to extreme environmental conditions like heat or cold temperatures. 

PUR also lays flatter since it takes less glue to hold the same amount of paper. EVA books can feel stiff and will tend to want to close. The superior durability compared with EVA glue systems making them suitable for applications such as textbooks, and high-end magazines or catalogs where quality is of high importance.

On the other hand, EVA glue systems are ideal for lower volume applications where high-quality binding strength is not critical. They offer a more economic option to perfect binding that isn’t reliant on producing extremely durable binds. Sometimes books are disposable or not intended to be kept for a long period of time.

When selecting a perfect binder, it’s crucial to consider the size and thickness of the books you will be binding. Production speed requirements, as well as the required level of quality are also essential. Understanding these factors will ensure you select the right machine to produce consistent high-quality bindings for your bookbinding needs.

The book publishing industry has long relied on perfect binding technology to produce high-quality paperbacks, hardcovers and other bound publications. In our region the Ann Arbor market of book publishers have installed a huge number of perfect binders. Book publishers use EVA and PUR interchangeably depending on the needs of their customer.

Perfect binding offers an efficient way to produce books in large or small quantities. This makes it an ideal choice for publishers who need to keep up with demand. The ability to customize covers with full-color printing makes perfect binding an attractive option for publishers who wish to create books that stand out on the shelves.

Corporate reports and brochures often require a professional look that is achieved through high-quality binding. Perfect binders are excellent for producing corporate reports and brochures since they can handle small quantities and small print runs without any set up or waste.

Using a thermal binder or other type of perfect binder, companies can present their information in a professional manner that will impress clients and investors alike. Using PUR on those types of presentations will make them look even more professional.

Catalogs and magazines rely on visual appeal as much as informative content. Using a reliable perfect binder ensures that these publications maintain their aesthetic appeal while also being functional. Even though magazines are thin they can still have a nice square binding even if it is only a quarter inch. Having the real estate to print a catalog or magazine title on the spine is an added benefit.

The use of PUR glue in these bindings ensures that each coated glossy sheet stays securely fastened with no risk of falling out. Whether printed on glossy paper or traditional newsprint, catalogs and magazines printed using perfect binders offer a professional look that is sure to impress readers.

Perfect binders are a staple component of the bookbinding industry and can be used effectively in a variety of other industries as well. From publishers to corporations to magazine editors, many professionals rely on perfect binding technology to achieve high-quality, professional results in their print materials.

As the demand for high-quality bookbinding continues to grow, so does the need for faster, more efficient production processes. Automated binding systems offer a solution by providing precise, high-speed performance that can significantly reduce production time and costs. Automated book binders are designed to create a sellable book on the first try. The goal is zero waste and no set up books going into the trash. 

Automation also lets inexperienced operators produce high quality books without a deep level of skilled trade knowledge. Being able to set up these machines with a touch screen makes them much more approachable to new operators.

In recent years, there has been a growing focus on sustainability in all industries. The bookbinding industry is no exception, with many manufacturers now incorporating eco-friendly practices into their production processes. One such innovation is the use of PUR glue instead of traditional EVA glue.

PUR glue offers superior bonding strength and durability compared to EVA glue while also being more environmentally friendly. Additionally, some perfect binders now feature energy-saving modes and reduced emission levels to minimize their impact on the environment.

Another notable sustainability feature is the integration of recycled materials into book covers. We can use reclaimed paper or cardboard for covers, maintaining both quality and aesthetics. Off white and kraft papers have become favorable choices for consumers.

As technology continues to evolve rapidly, we can expect even more exciting developments in perfect binding technology in the years ahead. One promising area of research involves exploring new materials that could replace traditional book glue altogether – such as adhesives made from soybeans or cornstarch.

In the production scene we have watched automation slowly grow throughout every part of the process. Recent trade show demonstrations have shown robotic arms loading book binder pockets with no human intervention at all.

Additionally, automation will likely continue to play a significant role in perfect binding processes as manufacturers seek to improve efficiency and reduce costs. We may also see more sophisticated sensors and other monitoring systems incorporated into perfect binders, allowing for even greater precision and quality control. Doing these tasks at a higher speed is something that becomes possible with new types of sensing.

The future of perfect binding looks bright as manufacturers continue to innovate and adapt to changing needs and demands. Whether you’re a book publisher, corporate report writer, or magazine editor, these advancements in perfect binding technology are sure to benefit your production process.

One of the most important aspects of maintaining a perfect binder is regular cleaning. The accumulation of glue, dust, dirt, and debris in a perfect binder can lead to various problems that can affect the quality and efficiency of binding. Perfect binders can become very dirty and glue is difficult to clean up especially after it sets up permanently. Glue stringing can be an issue that causes glue to accumulate in places.

To prevent this, it is recommended to clean the equipment thoroughly after each use. This involves removing any leftover EVA glue or PUR glue from the machine’s components using a scraper or brush.

If you are suffering from glue stringing, consider adjusting the book settings. Increasing the glue trap is the best recommendation but adding dwell times or adjusting the amount of glue can help as well.

Ensure that no residue is left on the book spine or cover before applying new glue. In addition to regular cleaning after use, it is also important to schedule periodic deep cleaning sessions.

This includes dismantling components such as clamps and knives for a thorough cleaning process. Dust and debris tend to accumulate in hard-to-reach areas within the machine over time, which can cause malfunctioning if not cleaned properly.

Proper lubrication is essential for maintaining optimal performance and longevity in bookbinding machines like thermal binders or perfect binders. Perfect binders use a lot of heat and that heat can cause lubricant to dry up. Lack of sufficient lubrication can lead to machine breakdowns, which results in costly repairs or replacements.

To avoid this pitfall, it is crucial to adhere to manufacturer recommendations on lubrication requirements. The specific type and quantity of lubrication may vary based on the brand or model in use.

Some machines may need daily lubrication, while others require weekly treatment, depending on their frequency of use. An insufficient amount of lube over time can result in friction build-up leading to decreased efficiency due to misplaced pages during binding operations that could cause difficulty when applying book covers.

Apart from regular cleaning procedures and proper lubrication techniques, performing preventative maintenance measures remains imperative for extending equipment life span while ensuring high-quality results. This involves performing frequent checks on the machine’s components to identify any signs of wear and tear.

Regular inspections help detect problems early enough before they result in more significant issues. Preventative maintenance measures for perfect binders include checking for any loose connections between the parts, verifying that the clamps are working correctly, and ensuring that the temperature settings are accurate.

Addressing these issues immediately helps prevent further damage to the machine, thereby saving on time and money spent on costly repairs. Following proper maintenance techniques is crucial for maintaining your perfect binder’s quality, efficiency, and longevity.

Regular cleaning procedures involving removing book glue residue from book spines and covers after each use reduces dirt buildup leading to malfunctioning issues. Informed lubrication techniques ensure optimal performance while following preventative maintenance practices prevents further damage to the equipment in use.

Thermal binding technology has been around for a while, but it is still evolving. Many manufacturers are investing heavily in research and development to come up with new and innovative ways of improving thermal binders.

Some focus areas include improving glue formulas, reducing heating times, and refining binding mechanisms for precision. With advancements like these, thermal binders will continue to be a popular choice for book binding. Book binding is far from becoming obsolete. In fact, we are witnessing an unprecedented surge in book production.

The book binding industry has come a long way over the years, and it shows no signs of slowing down. As technology continues to advance, new opportunities will arise for publishers and other book producers to create even better products.

The use of PUR glue has already revolutionized the industry with its superior bonding capabilities. Other advancements like automated binding systems have made book assembly faster and more efficient than ever before. We are proud to represent one of the top manufacturers of perfect binding equipment in the world so stay tuned to see what’s coming next in the industry.

As people become more conscious about the environment, there is an increasing demand for sustainable business practices across all industries. Book binding is no exception. Paper products are seeing a resurgence as consumers being to reject single use plastics in favor of sustainable products like paper fiber.

Manufacturers are now investing in eco-friendly materials like soy-based ink and recycled paper to create their products. They are also designing equipment that uses less energy and produces less waste over time.

This shift towards sustainability not only benefits the environment but also helps businesses save money in the long run. Perfect binding technology has come a long way since its inception.

From traditional EVA glue binders to modern PUR glue machines books must be recyclable. From manual assembly processes to automated systems – this industry shows no signs of slowing down in its pursuit towards high speed and greater volume. As we make continual advancements towards efficiency, sustainability, precision, and versatility, it’s evident that book binding will remain a crucial part of the printing industry and continue as a skillful art form in its own right.

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