Making a digital book

PDF files are received into production, onto the Bookstore software, within the digital manufacturing area. The Bookstore analyses which book-block imposition to use, creates a job ticket, and puts files into readable format.

Our complete in-line web-printing units ensure a high-quality, yet cost-effective, solution for short-run book production.
The printing engine uses LED technology ensuring that, with auto analyses of all 12,000 imaging diodes, maximum quality is always maintained at the printing stage. Calibration of each engine, both in image position and density, is constant, with quality assured.

On completion of printing, the printed web passes through a re-humidification unit, to reintroduce the moisture to the paper that has been lost during the printing process. This then travels through a buffer unit, allowing paper to stabilise. Cross cutting to long sixteens for folding then takes place, with either slot sections for paperbacks, or creased sections for sewn-cased. This then always dictates that the grain of the paper is in the direction of the spine.

The printing of any title is from first to last signature, with completed book-blocks being delivered from the digital print line. Post printing, these collated sections are bundled, and then stand for a minimum of 24 hours. This ensures the highest quality binding is achieved.

Paperback binding, and three-knife trimming, is carried out within the unit. The binder is a custom-developed, small, footprint binder from Wohlenberg. This complements the Champion E, which is used to produce lined book-blocks within the main bindery. This ensures consistent high quality, whether a paperback or cased product.