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Common bookbinding methods include saddle stitching, flat binding, sewn binding, and adhesive binding.
Among these binding techniques-such as saddle stitching, thread sewing, and adhesive binding-the central spread can be designed with a smaller margin. However, if the book is in paperback format, the cover's central spread should be relatively larger, as the binding edge of a paperback typically occupies approximately 5 mm.
In text layout design, various elements such as font size, line spacing, surrounding white space, title formatting (line height and blank lines), etc., all influence the overall cost of the book. For example, for a standard 32-page format book originally designed with a 5-point horizontal font, each page would contain 26 characters × 25 lines = 650 characters, with 5/8 line spacing between each line. For a manuscript of 240,000 words, this would require a total of 370 pages. If the layout is adjusted to 26 characters × 27 lines = 702 characters per page, with half-line spacing between lines, only 342 pages are needed. This results in a difference of 28 pages.
By optimizing aspects such as the number of pages, paper selection, and binding method, it is possible to reduce the overall cost of book production. Naturally, this does not imply that denser layouts are always preferable. For instance, in children's books, the font size should not be too small, and line spacing should remain adequate. Layout adjustments should be made based on the content and target audience, aiming to conserve materials while maintaining readability.
Determine the Cover Size Reasonably
When designing a book cover, considerations should include the finished book size, spine thickness, and flap dimensions. The flap size is generally recommended to be slightly larger than necessary, without causing waste or complicating the printing process, typically exceeding 30 mm. However, some designers may lack familiarity with paper specifications, sheet sizes, and printing machine capabilities. As a result, they may arbitrarily set the flap size without aligning it with standard paper formats. After plate-making, this often leads to mismatches with paper specifications and sheet sizes, resulting in unnecessary waste. Additionally, most book covers today require lamination after printing, which further increases production costs.
For example, consider a two-volume set, each being a large 32-page book with approximately 600 pages printed on 52g paper, yielding a spine thickness of 22 mm. The covers are offset-printed, with 20,000 copies produced per volume, followed by lamination. Due to insufficient knowledge of paper specifications and sheet sizes, the flaps were initially designed at 65 mm, necessitating the use of 787×1092 1/16 paper. However, if the flap size had been designed at 40 mm according to available paper dimensions, 787×1092 1/8 paper could have been used instead. This adjustment would result in savings of approximately 4,000 yuan in printing, paper, and platemaking costs. Therefore, when designing book covers, designers should possess a thorough understanding of paper formats and aim to minimize production costs to avoid unnecessary financial losses.
Some covers and inner linings feature relatively simple designs involving only a few spot colors and limited print runs. In such cases, copper-zinc plates may be considered during platemaking, and printing can be performed using letterpress machines. Since letterpress printing operates on individual sheets, leftover paper can be cut into smaller pieces for printing, thereby improving paper utilization and reducing both platemaking and printing expenses.
Binding Materials
When selecting materials for hardcover book bindings, the use of natural fabrics such as leather, cotton, linen, silk, and wool should be minimized. Instead, durable alternatives like tough paper, lacquered paper, or lacquered cloth should be prioritized. Except for special design requirements, the use of real gold foil for hot stamping should be avoided; aluminum foil or colored sheets can serve as suitable substitutes to reduce material costs.
Printing Technology
For general 32-page or 16-page single- or two-color books with print runs exceeding 50,000 copies, rotary printing presses are typically employed. These machines offer high-speed operation, pre-folding of printed pages, and lower printing costs compared to flatbed presses. However, for print runs below 50,000 copies, lead bars can be printed using large automatic, small automatic, or eight-page machines. Laser typesetting can be combined with B-B double-sided offset printing machines, which are specialized for books and periodicals and priced based on paper order. Alternatively, 01-type or 08-type single-color offset printing machines can also be used. These are single-sided printers, and their costs are calculated per color. Compared to single-color offset machines, B-B offset machines offer faster speeds and lower printing costs. For picture albums requiring high-quality printing, two-color or four-color offset machines are recommended. For large solid areas such as those found in New Year picture covers and inner linings, single-color offset machines are preferred due to their superior print quality.