WARE HOUSE OPERATIONS

The meaning of binding is to Fasten or to attach together. The main purpose of binding is to
keep the leaves of a book in order and to protect them.

The Ware house is the other term with us since a long time which is considered as the place
of practice where printed and blank stock is handled to convert it into finished product.

Thus Ware house has its nature – 1. White paper Ware house 2. Printed paper Ware house 3.
Practice paper ware house. That is actual execution of book binding work of all kinds.

The term Finishing process as applied to Binding is of fairly recent origin and has been
widely used to provide a modern title for the wide range of binding Operation.

Production Division in Binding and Finishing Process

Print Finishing Book Binding/Finishing Box & Carton

(Modern) (Traditional) (Modern) Manufacture

LetterPress Stationery Boxes

Cartons

(Printed Books) (Writing Books)

Corrugated Boxes Rigid Boxes

WAREHOUSE OPERATIONS

Warehouse in a printing industry is generally a paper store and it can be divided into two:

a) White Paper Warehouse

b) Printed Paper
‘White Paper’ means all kinds of paper of whatever color in an unprinted condition. Paper is
the foundation on which the whole structure of printing rests. Its care, handling and recording
are very important. Operations such as counting of the sheets, examining and rejecting of bad
sheet, folding, gathering, collating, stitching or sewing are done here.

COUNTING:

Printed sheets when received should be counted and compared with the work order figures.
Then only the forme should be allowed to be removed from the machines. There are counting
machines available in the market to deal with large quantities which may take many days and
need a number of men. Wrongly backed sheets, sheets with a smears, set-off, smudges, torn
sheets etc., are to be rejected. In colour work, sheets out of register are to be discarded.

JOGGING:

This is piling the sheets into neatly laid edges, expelling air and avoiding buckling. There are
machines for jogging purposes. Generally jogging is done before the sheets leave the machine
room.

PRESSING:

This is a very important operation for binding, without pressing the sheets will not be solid
and the book cannot be compact. Therefore, at various stages before final finishing the sheets
and the book undergo pressing.

FOLDING:

This is the earliest operation in binding a book. This may be done by hand or on a machine.
Full instructions are to be obtained before starting folding. About a thousand folds per hour
can be carried in modern times, this speed is not sufficient to cope up with mass production.

Therefore, folding machines with automatic feeders have been invented to fold four thousand
sheets per hour. The person wo is folding should understand the imposition and the number
of folds as well as the direction of the fold guided by signature and folios. A dummy folded
sheet should be available for guidance.

GATHERING
The process of assembling in their proper order the folded sections of a book. Gathering can
be done by hand with a revolving table with sections pilled in sequence mechanical gathering
machines are available for modern binderies.
COLLATING

Examining the cornered sections and rectifying any omissions among placing or duplication
of sections is called ‘COLLATING’. This should can be confused with collecting or
gathering which is different from collating.

STITCHING

When the whole book is passed through with a bodkin from the sides for thread or wire it is
called “STITCHING”.

SWING

Fastening together the sections of a book by chords or tapes. This is different from Stitching
adopted for cheaper class of work. Sewing can be done with the sewing frame in the bindery
work bench or by sewing machines.

LIST BRITISH STANDARD PAPER SIZES & SUB-DIVISIONS

Before the advent of ISO 216, England, the British Isles and the British Common wealth
countries used a variety of paper sizes.

The following table gives the sizes in inches of old English book, drawing and printing paper
sizes:

Size Paper Sizes Size Paper Sizes

Width x Height (in) Width x Height (in)
Foolscap 13.5 x 17in Double Foolscap 17 x 27in
Crown 15 x 20in Double Crown 20 x 30in
Demy 17.5 x 22.5in Double Demy 22.5 x 35in

Royal 20 x 25 in Double Royal 25 x 40 in

Imperial 22 x 30in Double Imperial 30 x 44in

Medium 18 x 23 in Double Medium 23 x 36 in

Post 15x 19 in Double Post 19x30 in

Elephant 20x 27 in Double Elephant 27x 40 in

 Size Paper Sizes
Width x Height (in)
Quad Foolscap 27 x 34in
Quad Crown 30 x 40in
Quad Demy 35 x 45in

SUB DIVISIONS OF PAPER SIZES

Rules of Sub Division Under British System:

1. A sheet folded in the middle of its long side makes two leaves of Folio or four
pages.
2. The Folio folded in the middle of its long side makes four leaves of Quarto or
Eight pages.
3. The quarto folded in the middle of its long side, makes eight leaves of Octavo or
16 pages.
4. The Octavo folded in the middle of its long side makes 16 leaves or sixteen mo &
so on.

QUARTO

FOLIO

16 MO
OCTAVO
8TO

8 32MO

1. Folio: 2 sheets or 4 pages

2. Quarto: 4 sheets or 8 pages
3. Octavo: 8 sheets or 16 pages
4. Sixteen Mo: 16 sheets or 32 pages
5. 32Mo: 32 sheets or 64 pages
Paper is usually sold by the ream of 480 sheets or by the quire of 24 sheets—20 quires
making one ream. The sheets are of various standard sizes the more usual of which are listed
overleaf.

The various sub-divisions indicated above are obtained by folding the standard size of
sheet—unless otherwise stated it is always the longest side of the sheet which is folded in
two.

INTERNATIONAL PAPER SIZES & SUB-DIVISIONS, RA & SRA SIZES,

ADVANTAGES OF ISO PAPER SIZES

The International Standard Organization (ISO) decided on a standardization of size and shape
of paper based on a square meter area and subdivisions of which retained the same
proportions, to make reductions and enlargements easier. These are also called as DIN Paper
sizes. For a number of years, the continental countries have been using a system of paper
sizes known as DIN (Deustsche Industrie Normen) currently referred to as International
Paper Sizes.

There are three sizes in this series: -

“A” :- Designed for all standard printing and Stationery purposes.

“B” :- For poster and wall charts and also for envelope into which “C” sizes envelopes can be
inserted.

“C”:- For Envelopes suitable for containing the “A” series (sizes) of stationery.

The “A” series is based on a rectangle having an area of one square meter, the sides of which
are in the proportion 1:√2 or 1.4142. This basic size has the description A0 when the sheet is
sub-divided each size of sub-division is designated by the letter “A” followed by an
appropriate figure.
 Size A Series Paper Sizes Size B Series Paper Sizes Size B Series Paper Sizes
Width x Height (mm) Width x Height (mm) Width x Height (mm)
A0 841X1189mm B0 1000X1414mm C0 917X1297mm
A1 594X841mm B1 707X1000mm C1 648X917mm
A2 420X594mm B2 500X707mm C2 458X648mm
A3 297X420mm B3 353X500mm C3 324X458mm
A4 210X297mm B4 250X353mm C4 229X324mm
A5 148X210mm B5 176X250mm C5 162X229mm
A6 105X148mm B6 125X176mm C6 114X162mm
A7 74X105mm B7 88X125mm C7 81X114mm

The “A” series is based on the dimension 841X1189 mm(A0) which is one square meter area.
Two larger sizes are calculated by doubling the short dimensions of A0 to give 2A0 and by
doubling both dimensions resulting in 4A0.
Regular subdivision of A0 sizes:
RA & SRA SIZES OF PAPER
Size Raw Series Paper Sizes Size SRaw Series Paper Sizes
Width x Height (mm) Width x Height (mm)
RA0 860X1220mm SRA0 900X1280mm
2RA0 1220X1720mm 2SRA0 1280X1800mm
4RA0 1720X2440mm 4SRA0 1800X2560mm
RA1 610X860mm SRA1 640X900mm
RA2 430X610mm SRA2 450X640mm
RA3 305X430mm SRA3 320X450mm
RA4 215X305mm SRA4 225X320mm
RA5 152X215mm SRA5 160X225mm
RA6 107X152mm SRA6 112X160mm
RA7 76X107mm SRA7 80X112mm

ADVANTAGES OF ISO PAPER SIZES

The International paper sizes were introduced to bring easyness in standardization in printing
industry throught the world. ISO decided and accepted these sizes in 1926. In India these ISO
sizes were accepted by Indian Standard Institute (ISI) in1956. Though these ISO sizes are
intended to phase/ quit out the traditional long nomenclatures of British Standard Paper sizes,
these will remain with us for a long time. Due to ISO paper sizes the printing industry has got
many advantages such as:

1. The size and shape( width & length proportional) of papers and books have become of
International Standard.
2. The paper being used for printing and stationary purpose i.e., “A” series is based on a
square is based on a square meter area. Sub-divisions of which retain the same
proportions, to make reductions and enlargements easier on process camera.
3. The principal sizes likely to be stocked are A0, A1, A2, RA0, RA1, RA2, SRA0,
SRA1, SRA2 and due to this exchange of paper, import-expert has become easier.
4. Due to GSM weighing system the quality of the paper can be ascertained
immediately.
5. The nomenclatures, their calculation confusion have minimised considerably.
6. Due to limited sizes the storage-investment has been reduced considerably.
 7. The main advantage goes to the paper manufacturers as they can concentrate on
production of limited sizes.
8. This system has simplified the production of printing, binding and other allied
machinery.
9. Due to the specific sizes of books(A5,A4) and stationary the filling system,
cupboarding, displaying of books has become easier. The sizes of shelves, cupboards,
racks, files, etc., also got standardised.
10. Due to the RA and SRA sizes, which provide standard trims, the book-sizes are
standard. Trimming of book got regularised.

JOGGING

Jogging means the printed sheets or blank sheets are knocked down at the gripper and side
lay side. Two opposite corner of few papers(100to200) are held in between thumb and fore
fingers, turned upward, pressured and stretched to allow the air to let in between the sheets.
This are-filling helps to knock down the sheets easily as static electricity is removed off.
After perfect jogging the air is removed off by pressure. This can be done by machine too. An
electro-mechanically vibrated tray collects the sheets at one slanted corner, positioning them
at their gripper and lay side.

COUNTING

To receive correct number of printed sheets in binding, to issue paper for printing, counting
of paper for printing, counting of paper becomes essential as paper is prime material. If one
sheet of one signature is lefts, it causes one complete book less in binding. Sheets are counted
in a pile of 250, 500, 1000 sheets as per their thickness, weight and size. For short run, hand
cutting is quicker, where as, for long run and security printings an electro-mechanically
operated counting device is used. Hand counting also helps to have over all check of the
printed sheets and torned sheets, mis-printed sheets can be removed off.

FOLDING, FOLDING TO PAPER, FOLDING TO PRINT LUMP FOLDING,

ZIG-ZAG FOLDING, HAND FOLDING, ADVANTAGES OF HAND FOLDING,
FOLDING SCHEME.

FOLDING

Folding is the process of preparing a section of a book or pamphlet by reducing its size
according to the imposition scheme. It is nothing but forming a permanent crease by crushing
the fibres of the sheet at the line of folding.
There are three types of folding.
They are
1. Folding-to-paper
2. Folding-to-print
3. Lump folding

FOLDING-TO-PAPER

Folding-to-paper means folding the paper to its edge to edge, particularly when the print area
is in irregular shape.

Requirements
 Equal margins on opposite sides.
 Accurate size of the form.
 All sides must be in right angle.

Advantages

 Faster method of doing.

Disadvantage

 Quality is less.

FOLDING-TO-PRINT

Folding-to-print means folding the paper exactly according to the print area. Any
irregularities in margin will be rectified in cutting. Particularly book work, magazines and
quality controlled jobs are folded print-to-print with fine registration.

Requirements

 Run-on headings.
 Folding marks.
 Perfect imposition.
 Equal margin.

Advantages

 Quality is more.
Disadvantage

 Speed of work is slower.

LUMP FOLDING

Lump folding means folding collectively say 5-10 sheets at a time. After folding the
individual sheets are separated. This is termed as “pulled”. After pulling or separating the
sheets are finally pressed to have a crease. Cheap quality book works are folded by this
method. The quality will be less but the speed of the work is very fast.

ZIG-ZAG FOLDING
Miscellaneous work is folded parallel Zig-Zag, accordion or in other ways. Time table,
advertisement folders and Price list etc., are folded in this fashion. The type of folding is
decided according to the size of the paper, number and shape of pages, number of copies to
be printed and the type of printing press.

HAND FOLDING

Hand Folding requires ordinary imposition of type. Pages for folding, machines require
special imposition schemes. This should be decided in the composing stage itself between
the binding and composing sections.

FOLDING SCHEME

The way in which the folds of particular forme are arranged, the type of folding or the
scheme of folding it will be called.

Folding schemes are based on: size of paper, shape, sewing style, printing style, imposing
scheme etc.

1. Right angle folds: while folding the paper, when the long dimension is divided and
then the second fold is made exactly crossing in right angle to first fold, that means
wherever the folds are crossing to each other making equal division in each direction
will be called as Right angle folds. Number of folds may be increased but they must
be crossing to prefixed one making further equal divisions. For example, 8 page,
16page, 32 page, 8-page landscape etc.

2. Parallel folds: When the second fold is exactly parallel to first fold making four equal
divisions of one dimension will be called as parallel folds. The number of folds may
 be increased but they must be parallel to previous folds making further equal divisions
in the same direction. For example, 8-page folder, 6-page zigzag, 6-page letter, wallet
fold, 16 page 2 up or 32 page 4 up etc.

PROCESS OF GATHERING, USES OF SIGNATURE, USES OF BINDERS MARKS,

TERM COLLATING.

GATHERING

Gathering is the process of collecting all the sections of a book in a proper sequence. In
manual gathering, all the sections of a book are stacked on a table in proper order. The binder
will collect one section from each pile, beginning with the last signature. Gathering must be
done with utmost care to prevent mistakes.

COLLATING

Collating is the process of checking a gathered book to ensure that all the sections are there in
proper order. It is also known as “Examining” and must be done before the securing
operation.

BINDER’S/COLLATING MARK

It is a black square mark printed on the spine of each section. The marks are printed slightly
offset in each section progressively. When the sections are correctly gathered the binder’s
mark on the spine side forms a step like appearance. By this we can identify the correctness
of the gathering. It easily shows missed, extra, mis-placed sections.

PROCESS OF ATTACHING PLATES CHARTS & MAPS

INSERTING
When the paper used for printing the text is unsuitable for printing the halftone illustrations,
they are printed on single leaves (coated paper) which are termed as plates. These plates are
then inserted in appropriate places of a gathered book before sewing. Sometimes the single
leaves are pasted after sewing. This operation is called as “inserting”.

ATTACHING PLATES OR MAPS

Sometimes folded maps or diagrams printed on a large sheet or board are also folded a little
less than the book size and pasted inside the book. This is also called as “inserting” or
“attaching plates or maps”.

EYELETING AND ITS USES

Eyelets made from brass, steel or aluminum is used to prevent the tearing of hole in a paper
or board. Rivets are used extensively in fastening of metal parts in paper products. Various
types of metal and plastic fasteners such as spiral, comb, inter screw, rings, metal backs etc.,
are used to hold loose sheets together.

Eyelet punch is a machine used for punching eyelet holes and fastening eyelets in paper,
board or cloth.
INDEXING AND TYPES OF INDEXING AND ITS USES
Indexing is extensively used in stationery work and it is essential on ledgers, account books
and diaries.
ONE LETTER INDEX: has one leaf allotted to each letter of the alphabet; I and J are
placed on one leaf and X is either omitted or placed nearly. So twenty-four leaves are
required.
TWO LETTER INDEX: contains two letters to each leaf – 12 leaves are used in smaller
account books. Ijk and xyz are taken on single leaf. Cut through index has all the leaves
allotted to each letter in proper proportion. To consider the proportion a small directory 12
leaves are used in smaller account books. Ijk and xyz are taken on single leaf. Cut through
index has all the leaves allotted to each letter in proper proportion. To consider the proportion
a small directory will guide considerable. The allotted sheets are cut up to bottom.
THUMB INDEXING: instead of cut through INDEX and cutting the whole sheets; the
sheets allotted to each letter are cut in a half round shape in which a thumb can be placed
easily.
TAB INDEXING: The above indices are useless for loose leaf binding in which the sheets
are not of even widths. For projection of each letter tab indices are used. A strip of cloth,
rexine, leather or plastic etc. are pasted over the sheets, these are printed with letters and for
strong attachment they are reinforced.
INDEX CUTTING BY HAND :- The length of the book is divided into 24 parts exclusive
margin. The first sheet is cut away by 23 parts and single part is left at the top of the page,
second sheet has two parts and so on until the index is complete. Last sheet i.e. 24th sheet will
not have any cut.
INDEX CUTTING MACHINE: Index is cut by machine to which ‘L” shaped knife is
attached with an adjustment either the knife to be moved to cut even divisions or the table to
move after every cut. The ‘Y” sheet is cut first and removed and ‘X’ is cut and so on up to
‘A’