775

7.1 Classification of Print Finishing Processes

Finishing (postpress) is a segment of the print pro- • Individual sheets trimmed sheets, cuttings
duction flow in which the printed product is given its • Folded sheets sheets in various sizes that
requested features of form and functions (fig. 7.1-1). are folded according to a
The end products produced in the finishing process certain, sometimes compli-
are therefore characterized by the design (shape) and cated pattern
the functions that are determined by the information • Newspapers gathered folded sheets
content. • Booklets inserted folded sheets with
The product variety of the finishing industry is illus- a cover, stitched with wire
trated in the overview shown in figure 7.1-2. or thread in the spine,
The following products are produced in the finishing secure binding
sector (the information content is not taken into • Brochures single or multi-layer
account): blocks, stitching or perfect

Data base

Printed
Consumer, End Customer
product
Information Sources

Plate, Printed
Originals etc. pages
Customer, Printing Postpress
Agency, Prepress process Distributor
Publisher (Finishing)
Data Data Data Data
Film, plate, etc. Paper, ink, etc. Material, etc.

Production flow
Storage
Consumables
Supplier

Fig. 7.1-1 Production flow of materials and data for the creation of printed products

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776 7 Print Finishing Processes
Printing Printed web
process Finishing process
Printed sheet
Fig. 7.1-2 Print finishing products
binding, cover (mostly
made of heavier stock)
• Hardcovers multi-layer block, thread-
stitching or perfect bin-
ding, cover consisting of
several parts (usually refer-
red to as a book)
• Assortment of sheets binding technique:
mechanical (very often
detachable), comb or spiral
bindings using metal or
plastic
• Packing material/ open or closed material, cut
means to size and formed to hol-
low bodies during the
packaging procedure.
Printed products, in particular book binding products
are usually assembly products, that is, they consist of
several partial products that have been produced
independently of one another:
• Block Carrier of the printed
information (book block,
content sheets)
• Cover Protection unit connected
with the body (case, cover,
file, folder, lid) or packing
material
• Finished parts Structural parts made of
metal, plastic, board, etc.,
Bookbinding operations
Books (hardcovers), brochures, calendars, forms,
posters, blocks, advertising inserts, mailings etc.
General paper processing
Technical paper goods (gaskets, stencils etc.)
Hygienic paper goods (serviettes, mats etc.)
Decorative products (punched figures, garlands etc.)
Office stationery (files, folders etc.)
Toys (model sheets, games etc.)
Teaching and learning aids (pads, booklets, globes etc.)
Production of packaging means
Packaging means (boxes, bags, tins etc.)
Packaging aids (labels, tags etc.)
Mail products (letter paper, envelopes etc.)
which need to be attached
to the product (e.g., bind-
ing mechanisms in files)
• Supplements Information and advertising
material that is added to the
body or the finished
product (inserted, glued).
They differ considerably in
their shape and comprise
graphical products (e.g.,
cards, booklets), mailings,
and samples
• Jacket A jacket that is put around
the actual cover of books
and brochures. Today jack-
ets serve mainly for adver-
tising purposes.
To analyze the organization of the processing proce-
dure it is useful to structure the finishing process into
individual process sections. Each section characterizes
the transformation of the material (partial product)
with regard to the desired processing outcome. The
designations of these processing sections use unique
terminology that has historical origins.
Rausendorff [7.1-1] made a suggestion for a process
classification in bookbinding (table 7.1-1). This struc-
ture can also be used for other print finishing process-
es. Section 7.2 is organized on the basis of this process
classification and therefore deals mainly with the pro-
duction of hardcovers and brochures.
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 7.1 Classification of Print Finishing Processes 777

Processes: Sheet/web Block production Casemaking Finishing

processing

Process Cutting Gathering to blocks Trimming the case material Assembling the product
sections Folding Binding blocks Jointing covers Shaping the product
Forwarding Trimming blocks Surface finishing covers Completing the product
Preparation of Rounding blocks Rounding covers Packing the product
processing and Coloring edges
functional points Joining of extra items

Table 7.1-1 Overview of the process classification in bookbinding

Cutting blocks
The following operations are carried out in the
process sections:
3 (Also referred to as trimming.) Blocks are
trimmed to the end format on three sides
(see sec. 7.2.6).
Cutting of webs and sheets
Paper webs or sheets are cut to a format that is
suitable for further processing (see sec. 7.2.1). Rounding blocks
Forming book blocks so that the block spine
Folding has a convex and the front trim a concave
Sheets or webs (book binding sheets) are fol- shape in the block thickness direction (see sec. 7.2.7).
ded once or several times so that connected
folded sheets or webs are produced at the folding Coloring edges
edges (see sec. 7.2.2). One or more block edges are covered for col-
oring with an ink or metal foil (see
Forwarding sec. 7.2.7).
Forwarding comprises all operations on the
folded sheet where a jointing procedure Jointing extra components
takes place (see sec. 7.2.3). Book marks, headbands (ornamented bands), or sim-
ilar materials are attached to the block (see sec. 7.2.7).
Preparing processing and functional points
Separating or forming operations are carried Trimming case material
out on partial products to prepare proces- Trimming cardboard covers, book cloths,
sing or functional points: and inserts for the case-making process or
• rule perforation as tear-off, gluing or bending trimming of jackets (see sec. 7.2.8).
edge,
• hole punching for positive jointing operations, Jointing covers
• scoring, grooving, creasing to fix a bending edge. Making a book case by jointing the cover
cuttings (see sec. 7.2.8).
Gathering to blocks
Producing an unbound block of independ- Surface finishing covers
ently produced and folded sheets of a book P Printing or embossing covers or jackets (see
or brochure in the correct sequence (see sec. 7.2.4). sec. 7.2.8).

Binding blocks Rounding covers

Creating a temporary or permanent connec- The cover spine is rounded in a forming operation to
tion of the collated folded signatures/ sheets conform to the rounding of the block spine (see
to a block by a jointing operation (see sec. 7.2.5). sec. 7.2.9).

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778 7 Print Finishing Processes

Casing in Completing the product

Jointing procedure of book block and case
(see sec. 7.2.9).
Forming the product
Comprising procedures for stabilizing the
glued joint, forming an opening hinge (fold)
and carrying out the book spine rounding (see
sec. 7.2.9).
Including putting on a jacket, inserting supplements,
and sticking labels onto the cover or the jacket (see
sec. 7.2.9).
Packing the product
The products are packaged individually or in
piles; packing of the transport unit (pallet
packaging) (see sec. 7.2.10).

Hard covers
Body Cover Supplement Jacket

Printed sheet Cover material Product Printed sheet

Cutting
Paper cutting Trimming cover parts jackets

Folding Folding
Jacket flaps
Forwarding

Gathering

Block binding Case making

Trimming
Surface finishing covers
Coloring book edges

Gluing book marks

Block spine rounding Rounding covers

Gluing headbands

Casing in

Book pressing

Joint burning

Inserting supplements

Jacket

Packaging
All process in a red box are essential for the
End product ready for dispatch production of hard covers.

Fig. 7.1-3 Process steps for the production of fancy books

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 7.1 Classification of Print Finishing Processes 779

The process sections have been assigned with symbols cover, block binding, and trimming would not take
(pictogram) that are used in the following to illustrate place.
the process flows. The collection of loose leaves in a binder is
Figure 7.1-3 shows an example of a manufacturing described in another example (fig. 7.1-5). For the most
process for hardcovers for fancy books. In practice we part the same operations are carried out as in the pre-
can distinguish between categories such as fancy vious examples. The preparation of functional and
books, simple edition bindings, school books, chil- processing points includes the producing of binding
dren’s books, and so on, which reflect the degree of holes in the spine of binders and punching the block
complexity of the book blocks and the extent of sur- as a preparation for the positive joint/linkage between
face finishing of book covers. The diagram (fig. 7.1-3) file and block by means of a mechanism.
describes the production process for fancy books from To assess a process step it is necessary to investigate
print sheets. All process sections inside a red box are the technical means (tools) used for the transforma-
essential for the production of hardcovers and repre- tion of the partial product. The way a material is
sent simple edition bindings. changed by a tool is referred to as the working
Figure 7.1-4 shows a possibility for processing method. A selection of working methods applied in
brochures. It becomes obvious that the assembly of finishing is listed in table 7.1-2.
block and cover takes place during the block binding A process step can in principle be achieved by sev-
process. All process steps in a red box are essential for eral working methods.
the production of brochures. Those process steps in a The “block binding” process step can be achieved by
green box are typical operations for the production of the working methods: stitching, gluing, or clamping,
magazines. In a description of the processing steps of the “surface finishing” process step can be achieved by
newspapers, the operations for the production of the the working methods: printing or foil embossing.

Fig. 7.1-4
Brochures
Operations for the production of brochures
Body Cover Supplement

Web Jacket sheet Product

Cutting Cutting the cover

Folding Surface finishing the cover

Gathering

Block binding

Trimming

Inserting supplements

Packaging

Addressing

End product ready for dispatch

Operations that are inte- All steps in a red box Operations that need to
grated in web offset are essential for the be performed for the
presses production of brochures production of magazines

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780 7 Print Finishing Processes

Fig. 7.1-5
File with block
Process steps for the production of files
with an assortment of loose leaves Body Binder Finished part

Printed sheets/web Case material “Mechanism”

Cutting Trimming file

components
Folding
Case making
Gathering
Surface finishing
Trimming cases

Preparing Preparing
processing points functional points

Mounting the file

Completing the
file

Packaging

End product ready

for dispatch

Basic method
Forming Separating Jointing Coating

Forming the print Dividing Positive linkage Coating from liquid, pasty
– Blind embossing – Cutting – Stitching or solid state
– Pressing – Die-cutting – Screwing – Brushing
Method groups/Working methods

– Scoring – Inserting, bending – Spraying

Bend forming – Perforating – Crimping – Rolling on
– Folding – Printing
– Creasing Metal cutting Bond linkage – Foil embossing
– Rounding – Milling – Gluing
– Pleating – Sawing – Welding
– Drilling – Sealing
– Grooving – Perfect binding

Dismantling Non-positive linkage

– Separating – Suction
– Clamping
Changing the physical
state Loose linkage
– Drying – Gathering
– Collecting

Table 7.1-2 Overview of method groups and working methods applied in finishing

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 7.1 Classification of Print Finishing Processes 781

Operator of machines and systems

Link-up of process sections Conveying working objects

Buffer for uncoupling workflows in

Temporary storage Reel store
the case of stoppages

Feeding, Delivering,
Unwinding Winding
Loading Unloading
webs webs
(general) (general)

Diverting the Uniting Product

product flow product flow switch

Coil with
Pallet with semifinished Pallet with folded sheets
products or end products sheet bundles (sheet disk)

Sheet pile, Staggered or

Product pile crosswise stacked

Fig. 7.1-6 Description of symbols for the structuring of processes

The description of methods makes finishing com- machines, transporting, temporary storing of semi-
parable with other engineering sciences since they finished products and products) must be considered.
apply the same working methods (e.g., scoring, die- For a better understanding of the process flows, fre-
cutting, milling, welding, spraying). But there are also quently used logistics symbols are illustrated and
working methods, such as folding, pleating, perfect described in figure 7.1-6.
binding, crimping, or gathering, that are exclusively
used in the graphic arts industry. In these cases the References in 7.1
process section and working method have an identical [7.1-1] Rausendorff, D.: Beiträge zur Systematik der
designation. Verarbeitungstechnik. Habilitation, TU-Chemnitz, 1981.
For the description of finishing processes (see
sec. 7.3), logistics processes (loading, unloading of

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