Technical Articles
Some Things Should Just Layflat
Published in New England Printer & Publisher
by Frank Shear
Here's a bold statement. Books are more useful when their pages layflat. Even though mechanical binding methods (Wire-O™, plastic spiral, spiral wire and GBC) are more expensive than traditional perfect binding, they have remained popular for many years. However, sometimes the high cost of mechanical binding is just too much to get around. A solution to this dilemma became available when Otabind International developed a cost effective layflat adhesive binding method. In 1992, Seaboard Bindery began offering layflat binding to New England printers for the first time. Here's why.
At first glance, layflat adhesive and perfect bound books look similar. Upon closer inspection, a significant difference becomes apparent. A layflat adhesive bound book's spine is detached from the book block, which allows the pages to open at a wider angle without straining the binding. Unlike traditional perfect binding, where the spine of the book block is glued directly to the cover, the pages of a layflat adhesive book are glued to a paper or cloth "crash" sheet. Then, the pages are glued to the inside front and back cover along the sides of the book block.
Readers notice a huge difference when using layflat adhesive bound books because these products lie relatively flat when opened on flat surfaces. If creasing is necessary on the first or last few pages of a book, only minimal pressure needs to be exerted, unlike a perfect bound book, which usually requires the spine to be creased so hard that it breaks. In addition, even frequently used layflat adhesive bound books maintain wrinkle-free spines and a good appearance throughout their lives. In short, layflat adhesive bound books are extremely user-friendly.
As with any postpress operation, understanding and managing the production process will prevent unforeseen problems. When you are asked to bid on a mechanically bound project with a large quantity, separate yourself from your competition by introducing your client to the benefits of cost-effective layflat adhesive binding. If layflat adhesive binding is right for their project, you will be perceived as bringing more value to the table and should win the job.
What is Otabind?
The main methods of layflat adhesive binding are Otabind™ and RepKover™. Otabind has steadily increased in popularity throughout the 1990's and is now the preferred binding method of many companies. Common applications include software manuals, cookbooks, textbooks, reference books, instructional materials and other books that need to lie flat so readers' hands can remain free.
The Otabind process involves applying glue down the spine of a book block to adhere pages to a crash paper liner. Once the pages are attached to the crash sheet, glue is applied to the sides of the book block, gluing the cover in place. The Otabind method not only yields a higher quality binding, but it is significantly cheaper than its nearest substitute layflat product - mechanical binding. Mechanical binding is material and labor intensive and production run speeds don't even come to matching that of Otabind.
Otabind Tips
Keep in mind some layout rules of thumb when planning Otabind jobs. In general, layflat adhesive binding can accommodate books up to 2" thick. As with all adhesive binding styles, the grain of the paper should run parallel to the spine, which maximizes binding strength. Although some binderies offering Otabind services shy away from coated stock, frequently these projects can be successfully bound if the text stock grain is parallel to the spine and PUR (polyurethane reactive) glue is used in conjunction with Otabind.
When planning Otabind projects, keep your copy, varnish and other coatings at least œ" away from the spine on the inside front and back covers and on the first and last text pages of the book block. Since side glue is used to bind the cover to the book block, this œ" clearance is needed to avoid the extra hinge scores required by Otabind. (Otabind covers have two hinge scores, positioned Œ" and œ" away from the spine on the outside front and back covers.) Plan your copy on the cover appropriately. For uncoated text, it's best to keep your grain direction parallel to the spine; for coated text, it's critical. Generally, Otabind is the best layflat option for large quantities or for books with covers thinner than 10pts.
RepKover Binding
RepKover is another layflat adhesive binding option that's enjoyed an increase in popularity. Covers for the RepKover binding method are produced separately from the book block. A wide cloth strip is glued along the spine of the inside front and back covers with cold PVA glue. Next, glue is applied to the book block and the pre-assembled cover is properly positioned and affixed in place. Since RepKover has a quick makeready, it is an excellent alternative to Otabind for layflat projects with small quantities.
When laying out a RepKover book, ask your bindery how far the cloth strip will extend up the inside front and back cover. Then, keep your inside cover artwork away from the spine by at least this margin, which is usually œ". Unlike Otabind, copy can run right to the spine on the first and last pages of the book block - of course after grind-off margin allowances have been planned for.
Polyurethane Reactive (PUR)
Glue for Superb Strength A few years ago, if you wanted to be certain that your pages wouldn't fall out, expensive smythe sewing was about the only option available. Today, exceptionally strong PUR glue accomplishes the same result at a fraction of the cost.
PUR glues can be used in either the Otabind or RepKover processes. PUR glue adheres to paper substrates better than regular hot-melt EVA (ethylene vinyl acetate) and cold-emulsion PVA (polyvinyl acetate) adhesives. PUR glue bonds effectively to thick paper stocks, lacquer coatings, UV coating, Mylar and more. PUR's strength and flexibility is outstanding. It works on any type of stock and performs well even under the most adverse conditions.
PUR glue wrinkles backbones less on cross-grain jobs because it is applied at a lower operating temperature and doesn't drive moisture from the backbone like normal hot-melt glues. For recycling purposes, PUR glue can be separated out, so the paper can be recycled. Although PUR glue's raw material cost is greater than that of other adhesives, less of it is needed to create an effective bond. For the right projects, thinly applied PUR glue sometimes can be an effective substitute for layflat adhesive binding. Although "PUR-only" adhesive binding doesn't have a flexible crash sheet, and doesn't lie quite as flat as Otabind or RepKover, it may be an attractive option for projects with lower budgets.
When your book project needs spine printing, layflat adhesive binding is a better choice than mechanical binding. Like perfect bound books, layflat adhesive bound products can easily be seen when filed away on bookshelves. If you are outsourcing layflat adhesive binding, ask your bindery representative what type of layflat binding they use. There are unlicensed Otabind and RepKover knockoffs available in the marketplace. While some of them may function reasonably well, others may cause disappointment.
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By consulting with a qualified post press house about new binding methods, not only will you avert potentially high production costs, you may discover unexpected solutions that uniquely and effectively meet your customers' needs. Offer layflat binding to your customers and prospects and sell more printing because - some things should just lay flat.
Frank Shear is President of Seaboard Bindery, a service-oriented trade bindery located in Woburn, Massachusetts. His company specializes in offering high quality perfect and layflat adhesive binding, saddle stitching, Wire-O™, plastic spiral, laminating and other bindery solutions. Call Frank at (781) 932-3908.