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Finishing

Designers who have taken the trouble to choose environmentally sustainable paper, low-VOC ink and a design that minimizes paper waste will want to be sure that all their efforts are not wasted through finishing techniques that hamper the ability of their projects to be recycled.

Coatings

Varnishes, aqueous coatings and UV (ultraviolet) coatings are often applied to printed coated papers to provide protection or enhance their appearance. Coatings are rarely applied to uncoated stock, as these papers absorb ink, minimizing scuffing and the need for protection. In addition, coating provides little visual enhancement on uncoated stock, as it absorbed into the paper rather than styling on the surface. When coatings are applied as an offline process over dry ink, the create a bold effect; but when applied as an inline process, they create a much more subtle effect over ink that is still wet.

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Overprint Varnishes

Applied during the printing process or as an offline process, overprint varnishes are much like solvent-based inks. They are usually colorless, but can be tinted to achieve a desired effect. Varnishes can be applied as an all-over coat, or in spots to highlight a specific area, and are available in glossy, dull, satin or matte finishes. Gloss varnish creates a smooth surface over the paper, filling in voids or irregularities. Applying gloss varnish to a subject, and dull or satin varnish to the background, can create a nearly three-dimensional effect. The effects that can be achieved are endless when using different combinations of varnish, paper and ink.

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Aqueous Coatings

Aqueous coatings are usually applied during the printing process as an all-over coat, or in patterns or spot coatings. Like varnishes, they offer protection, provide numerous effects for print applications and are available in dull, gloss, matte and satin finishes. Among the advantages that water-based aqueous coatings have over solvent-based varnishes is that they will yellow less over time. In addition, aqueous coatings, which dry instantly, are sometimes applied to uncoated papers to dry coat the ink so that the paper may be turned immediately for backside printing or binding.

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UV Coatings

UV Coatings come in a solventless liquid or paste form and remain a liquid or paste until exposed to ultraviolet light. The printed page is covered with the UV coating and is then exposed to UV light, causing photoinitiators within the coating to immediately react and harden the coating into a protective finish. UV coating–an energy curable coating–provides the best surface properties and protection for printed surfaces, but is also the most expensive coating option.

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Other Coatings

Like UV inks and coatings, EB (electron beam) is an energy curable coating, but it is hardened with the use of a concentrated beam of of high-energy electrons. EB inks/coatings do not contain photoinitiators because the high-energy electron beam is all that is necessary to cure the surface. Other types of coatings include clay coatings to add strength and gloss to paper, whitewash coatings used as a finish coat for such items as kraft paper and grease-resistant coatings used on applications for industrial and scientific uses.

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Bindings

Wire rolls and plastic combs

Both wire rolls and plastic combs are recyclable as long as they are separated from the printed pieces. Consider including a note to end users on the printed piece with instructions on how to recycle.

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Spiral

A spiral binding is a continuous wire that is coiled through holes that are punched into the pages of a book. The spiral wire can be made of metal, plastic or plastic-coated metal. Plastic is available in a variety of colors but the metal spiral has a limited color selection. When the book is open, the pages lie flat and can be folded over completely, which makes spiral binding a good choice for training manuals, cookbooks, notebooks, and calendars.

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Double Loop Wire

Double loop wire binding consists of a series of double wire loops from a continuous pre-formed wire that are inserted into pages that have been punched with square or round holes. The loops of wire are held open by a machine to allow the pages to be inserted over the loops. Once the loops are closed, extra pages cannot be added. Double loop wire binding is more expensive than plastic combs or spiral methods, but is more attractive and long-lasting. Pages will lie flat when opened and can be folded over completely. Double loop wire works best for books of one-inch thickness or less. This method is often referred to as the Wire-O® binding– a popular brand name.

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Saddle stitching

Metal staples that are used in binding do not need to be removed for recycling in most municipalities. Staples are removed at the recycling pulp mill using magnets, screens and filters during the repulping process. Although the staples are not themselves recyclable, this is still a good option.

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Side stitch

With side wire stitching, staples are inserted into the pages in the inner margin. The staples are inserted from the front side of the book through the pages to the back. Side wire binding can be used when the book is too thick to be saddle stitched. Side wire binding doesn't allow the book to be opened flat and an extra allowance for the inner margin must be made to allow for the staples. Covers for these books are usually scored so that they can be opened easily and neatly. The binding area can also be covered with decorative tape not only to hide the staples, but also to provide added strength to the binding and make the book easier to handle.

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Perfect-bound adhesives

In order for perfect binding to be recyclable, all adhesive residues must be removed from the paper fiber. Hot-melt, petroleum-based glues are hard to remove during de-inking. Water-based, non-chlorinated glues, however, break down easily during the recycling process.

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Other Finishing

Embossing

Using no chemicals or inks, this technique of creating a raised or receding image is an environmentally friendly way to add dimension. The die can be reused and it also works beautifully on uncoated paper.

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Watermarks

Watermarks are often added to paper as a means of identifying the manufacturer, adding a security feature or providing a customized design for the end user. Many higher-end papers are manufactured with a watermark incorporated into them. The watermark usually depicts a logo, a description of the paper type or mill where the paper was produced. Watermark images are invisible or difficult to view unless held up to light or held at an angle.

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Foil Stamping

Foil stamping, also called leaf stamping, creates a smooth opaque finish that contrasts with the texture of the paper. Stamping films usually come in two types: metallic and pigmented. Metallic films stamps are cleaner on paper; however, pigmented films have a much wider selection of colors. Recent studies indicate that foils are removed through the normal de-inking process used in recycling paper and are biodegradable.

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Scoring & Folding

Scoring is the process that places a crease in the heavier weight stock, allowing the stock to be folded for some type of assembly procedure. Scoring forms a "hinge" which helps relax the fibers and prevents them from pulling apart during the folding process. Effective scoring techniques depend on the weight of the paper. Scores produced on letterpress provide better results on heavy weight text and cover sheets than those of litho scores or scores made on folding machines. The most effective of the letterpress scoring methods are rule and counter, wire and rule, and channel creasing matrix. Hot scoring will improve folding and reduce the possibility of cracking.

Folding follows scoring. How well a paper folds depends on its weight and the direction of the fold. While folding lightweight papers is usually not a problem, heavier weight papers will need to be scored. It's important to score so that the ridge of the hinge is on the fold. This results in the paper being stretched less and the fold being stronger. Folding with the grain will result in a smoother fold. When a fold is applied against the grain of the paper, the resulting fold may have a ragged appearance and will cause the publication to "mouse trap" or close.

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Die cutting

In this method, the die acts like a cookie cutter. Similar to embossing, there is no use of chemicals or inks and the die can be reused. This is another environmentally friendly way to achieve a dramatic effect that works well on uncoated paper.

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Punching

Punching is the process of creating small holes along one edge of a document. Holes may be punched though press punching or bindery punching. Press punching is the process of punching holes on a web press at the same time that the product is being printed. Bindery punching is the process of punching the holes as an "offline" operation in the bindery. Click here for press punch configurations

• Standard configurations for press punching are:
• Two holes, 2 3/4" center-to-center, top or bottom
• Three holes, 4 1/4" center-to-center, left side
• Bindery punching
• Standard configurations are same as press punching
• No restrictions on non-standard configurations
• More expensive due to the labor involved
• Necessary specifications
• Number and diameter of holes (Ex. 3 holes, 1/4" diameter)
• Center to center measurement of hole placement and location of holes (Ex. 4 1/4" center-to-center, at left)

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Perforations

Perf cutting or perforating is an alternative to die-cutting that doesn't fully trim the desired materials away from the original shape, but instead creates a cut-out area that remains in place. This process is used when a desired section is to be removed from the document, but not immediately. The intent is to have the perforated area remain on the document until it is removed later by the consumer or a secondary process. Perforations or "perfs" are generally classified for print specifications through burst and tear strength or ties per inch.

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Engraving

The complicated engraving process involves etching designs into dies, inking the dies and pressing the die to paper. This classic and typically costly technique imparts elegance with minimal environmental impact, as most engraving inks are water- or vegetable-based.

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Signing Off

Once the job is on press, the results of the planning process become evident. A well-planned job will yield few surprises; a poorly planned project can hit costly snags. To the right are a few things to pay particular attention to while reviewing the press sheet. When satisfied with what is seen, sign off on it. Ask the printer for a few additional approved sheets to take for records.

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