1、 Core parameters of the product
（1） Basic specifications
1. Format size: Supports
customized production, with standard mainstream sizes including
32 open (finished size: 130mm × 184mm)
16 open (finished size: 185mm × 260mm)
Large 16 open (finished size: 210mm × 285mm)
Special sizes can be precisely cut according to customer needs (such as irregular format, customized aspect ratio), with an error controlled within ± 0.5mm.
2. Page range: 50-1000 pages, suitable for different thicknesses of paper. By accurately calculating the spine thickness (formula: page number x paper thickness x 1.05 loss factor), the spine is ensured to be flat and wrinkle free.
（2） Paper selection
1. Text paper
Common materials: 70g/80g pure paper (suitable for text-based books, delicate texture, non reflective), 80g/100g copperplate paper (suitable for graphic and textual books, high color reproduction), 100g/120g special paper (such as beige paper, ivory white art paper, enhancing high-end texture).
Environmental standards: All use FSC certified paper, which meets the environmental requirements of GB/T 10335.3-2022 "Coated Paper and Paperboard Part 3: Copperplate Paper", has no odor, and is biodegradable.
2. Cover material
Sealing paper: 250g/300g copperplate paper, 300g/350g special cardboard (supporting processes such as hot stamping, UV, embossing, etc.);
Binding cloth: imported/domestic pure cotton cloth, PU imitation leather, velvet cloth (color can be customized, color fastness ≥ 4 levels, wear resistance ≥ 500 times);
Special materials: leather (top layer cowhide, imitation leather), wooden board, metal nameplate (suitable for high-end commemorative and collectible books).
（3） Core parameters for binding
1. Spine structure: adopting a "round spine" or "square spine" design
Round spine: The curvature is one-third of the thickness of the spine (such as a 20mm thick spine with a curvature of 6.7mm), making it more comfortable to read and suitable for books over 150 pages;
Square spine: with a right angle accuracy of ± 1 ° and sharp lines, suitable for minimalist style or thin
Hardcover books (50-150 pages).
2. Locking process: Double reinforcement using "locking glue"
Lock wire specification: Each 32 pages is one thread, using 21 high-strength cotton threads with a needle spacing of 8mm ± 0.5mm, and the thread trace is flat without jumper wires;
Adhesive: Imported EVA environmentally friendly hot melt adhesive with a bonding strength of ≥ 50N/25mm and a temperature resistance range of -10 ℃ -60 ℃, ensuring long-term adhesion.
3. Hot stamping parameters: supports processes such as hot stamping, silver stamping, and gold stamping
Hot stamping temperature: 120 ℃ -150 ℃ (adjusted according to material, copperplate paper 120 ℃ -130 ℃, fabric surface 140 ℃ -150 ℃);
Pressure control: 3-5kg/cm ², hot stamping clarity ≥ 98%, no leakage or sticking of the plate, adhesion test (no peeling after pasting with 3M tape).
2、 Refined production process
（1） Pre processing stage
1. Document review: A professional typesetting team conducts a "three review" of the PDF files provided by the client - review resolution (text image ≥ 300dpi, cover image ≥ 350dpi), color mode (CMYK mode, to avoid RGB color cast), and bleed position (3mm standard bleed, to prevent white cutting). After approval, a sample confirmation draft is issued.
2. Paper pretreatment: Conduct "moisture adjustment treatment" on the paper to control the moisture content of the paper at 6% -8% (dynamically adjusted according to environmental humidity), avoiding paper deformation and warping during later cutting and binding processes.
（2） Printing stage
1. Inner text printing: Heidelberg CD102 four-color printing machine is used, with a printing accuracy of 175 lines/inch and a color deviation of ≤ Δ E2.0 (in accordance with ISO 12647-2 standard). Before each batch of printing, a "color code sample" is printed, and after customer confirmation, mass production is carried out to ensure uniform color of the entire batch of books.
2. Cover printing: The cover adopts "multi process overlay printing", and the text part is partially polished with UV (to improve wear resistance, no fading after friction ≥ 300 times). The graphic and textual parts can be overlaid with hot stamping and embossing/embossing processes (embossing height 0.3mm-0.5mm, clear edges without burrs).
（3） Binding stage
1. Text processing:
Cutting: German Pola 115 paper cutter, with a cutting accuracy of ± 0.1mm, ensuring that the page numbers of the text are aligned and there are no "slanted pages";
Lock thread: Fully automatic lock thread machine, capable of processing 300 threads per hour, with uniform thread patterns. After each thread is locked, it is "knocked flat" to ensure the smoothness of the content.
2. Spine production:
Round spine production: Use a "spine rounding machine" to press out the curvature of the locked inner text, and then wrap it with 120g kraft paper as the "spine core" to ensure that the curvature is durable and not deformed;
◦ Square spine production: After the inner text is sewn, the spine core is directly pasted and flattened with a "square spine shaping machine" to ensure that the spine is at a right angle and flat.
3. Cover production:
◦ Pasting: The printed cover paper/binding cloth is bonded to a 2mm thick gray board (or 1.5mm thick density board) using a "fully automatic pasting machine" with a pressure of 5kg/cm ² and a bonding time of 15 seconds to ensure no bubbles or wrinkles;
Edge trimming: After pasting the cover, use an "edge trimming machine" to cut off excess corners with an accuracy of ± 0.2mm and smooth edges without burrs.
4. Assembly and molding:
◦ Shell: Align the inner text with the cover accurately (with an error of ≤ 0.3mm), use a "shell machine" to bond them, and then use a "
book press machine" to apply pressure (8kg pressure, holding time of 30 seconds) to ensure that the cover is tightly attached to the inner text;
◦ Forming: After assembly, the books are placed in the "forming rack" and left to stand for 24 hours (ambient temperature 25 ℃± 2 ℃, humidity 50% ± 5%) to allow the glue to fully cure and avoid deformation of the spine.
（4） Post quality inspection and packaging stage
1. Quality inspection standard: Each book must pass the "five quality inspections"——
Appearance inspection: There are no scratches on the cover, no defects in the hot stamping, and no missing or inverted pages in the text;
Size inspection: finished product size error ≤± 0.5mm, spine thickness deviation ≤± 1mm;
Binding inspection: no missing pages when flipping through, no cracks on the spine of the book, and no looseness at the locking thread;
Color inspection: Randomly select 10% of books and compare them with color code samples, with a color deviation of ≤ Δ E3.0;
Environmental inspection: For each batch submitted for inspection, the formaldehyde emission should be ≤ 0.1mg/m ³ (in compliance with GB 18587-2017 standard).
2. Packaging method: Supports customized packaging, commonly using "single OPP bag+
cardboard box" packaging (cardboard box hardness ≥ 5 layers of corrugated, compressive strength ≥ 1500N).
High end books can be paired with dust-proof boxes (material: 2mm thick special paper pasted with gray board) and handbags to ensure no damage during transportation.
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