Two More Award Winning Binding Projects

More Award Winning Binding Projects from PBS

2007 Award of Recognition

Category Name: Special, Unusual or Difficult Folds

Title of Entry: Coca-Cola Coins

200,000 pieces. Cut and fold 5up on 28 7/8” x 18 1/2”; 9 accordion folds to 2 5/8” x 18 ½” then cut apart to 1up 2 5/8”x 3 ½”. Reading the description alone describes how complicated this job was, the result more than met the customer’s needs and expectations. The paper was supplied to us flat, wrong grain and not prescored. This piece is unique in that it contains nine accordion folds, the most we have ever done on our folders. The only way possible to achieve nine accordion folds was to go through two-six plate units on our folders using six plates in one and four in the second. Cracking along the spine was minimal and also unavoidable unless pre-scored. The final product laid flat and lined up beautifully.


2007 Certificate of Merit

Category Name: Creative Use of Folding in Conjunction with Die-Cut Pieces

Title of Entry: Bodog Wallets

101,000 pieces. Insert “bill” into pre-diecut wallets, then fold and cold glue to form wallet. This was a very interesting piece because all of this was done in one pass through the folder. It was done in the most efficient way possible through some creative problem solving once again. The normal way of doing this would be to tip the bill onto the flat wallets with fugitive glue and then fold the wallets and cold glue in-line. However, this was not efficient as it required two operations. Our operators used our Longford tipping machine and attached it to the folder. Instead of tipping the bill into the wallet, they inserted it using the Longford and then applied two strips of glue before folding it into the final piece. This method was something new for us because it had numerous factors that could have caused it to fail. For example, if the bill was inserted too far down, it would have dog-eared when the wallet was folded. The timing had to be perfect. The bill was almost completely centered; for an uncontrolled process, we achieved excellent results.

Glue Folding Award

2007 Printing Industries Association Award of Recognition – Glue Folding Award

Category Name: Creative Use of Glue in Folding

Title of Entry: Travel Alberta

260,600 pieces. Two accordion folds with three lines of glue on one panel to adhere to second panel. This piece was cut, perf’d, scored, glued and folded.

This was a promotional piece done for Travel Alberta in which there were four pop up windows with a different picture underneath it. The folding of this piece had to be on the dot as there was little room for movement beneath the panels. There were slight bleed allowances, however, the three panels must match up accurately for the piece to look complete, and any white space would have ruined the effect.

There were six versions to this piece and in one version the coating was not “knocked out”, therefore it required hot fugitive glue. If our operators had not noticed this, the final piece would not have stayed together with standard cold glue.

Fugitive glue is normally used for removable pieces, while using it in this instance was a creative solution to a tricky problem.

Graphic Finishing Award

2007 Product of Excellence Award (Best of Category, BIA)

Category Name: They Said It Couldn’t Be Done – Graphic Finishing Award

Title of Entry: Atelier on Robson

2700 books. Cut cover, tip on offset sheet, PUR perfect bound and trimmed, 9” x 14 ¾” 12 pp + foldout + cover, then apply preformed pocket to inside back cover. A double thick Kromekote Silver-one-sided cover made this job extremely challenging and the graphic finishing award winner of its category.

“It scratches if you LOOK at it!” says Irene, one of our handwork specialists.

This stock was extremely difficult to put onto the machine because everything from fingerprints to general handling would leave abrasive marks on this shiny stock. In order to prevent the cover from marking, our team of handwork specialists tipped on a sheet of offset stock to the outside of the cover so it was possible to run it through the machine. There is one foldout on the inside of the book that was inset 1/8” from the face. Additional challenges: after the book was perfect bound, it had to be trimmed on three sides offline in two to three books per lift to prevent chipping at the edges.

In addition, a pre-formed pocket had to be affixed onto the inside of the back cover with D-tape. Because the perfect bound book had gone through offline three-knife trimming, the offset sheet that was tipped on earlier was now only loosely protecting the cover. To take it a further step in ensuring the highest quality, our office administrator went to a local fabric store to purchase 90” x 4 yards of fabric for our handwork area. The fabric was used to protect the front cover in case the offset sheet fell off while taping on the pocket.

The final product is an impressively high gloss foil book with minimal marks, a D-taped pocket and a foldout page; this is a very high end book for a very high end client.

And they said it couldn’t be done.

PBS wins its Third PIA Benny Award

2007:  PIA Benny Award for PBS

Named after Benjamin Franklin, the Benny Award is the highest accolade from industry peers

For the third year in a row Pacific Bindery Services won the prestigious “Benny” from the Printing Industries of America – Premier Printing Awards for Best of Category – Adhesive Binding, Stepped or Indexed Products. To our knowledge, no other bindery in North America has won three Benny Awards in a row.

Benny Award (Best of Category)

Category Name: Adhesive Binding: Stepped or Indexed Products

Title of Entry: Drop Designs

2500 books. 22 pages + 7 dividers + cover 8 ½” x 11” perfect bound book. The text and dividers were cut, diecut, gathered, PUR perfect bound, trimmed at head and foot and 3-hole drilled.

The difficulty was in ensuring the careful handling of the job as the covers were full bleed and could scuff easily. As the tabs were die cut, it was easy for the corners to hit an object causing it to be blunt or bent.

Another difficulty of this job was in aligning everything at the face so that none of the tabs overhang the cover.

We did not do the die cutting; therefore the only variable we could control was the spine grind. The final product exceeded the expectations of our customer.