Board books are a popular format for young children thanks to their durability. If you’re considering self-publishing a board book, understanding the printing process is key. In this comprehensive guide, as a professional board book printing manufacturer, I’ll walk you through everything you need to know about how board books are printed.
An Introduction to Board Books
A board book is a book printed on thick paperboard or cardboard rather than normal paper pages. The pages are then laminated for extra protection. This makes board books extremely durable – perfect for infants and toddlers.
Board books are designed specifically to withstand rough handling from little hands. Their sturdy construction means they can be chewed, dropped, thrown, pulled, and tugged without falling apart. Try doing that with a regular paperback!
Board books are printed in a specialized way to create this level of durability. The process involves several key steps that I’ll outline throughout this guide.
Key Differences From Typical Book Printing
Printing board books requires different equipment, materials, and binding techniques compared to normal paperback books. Here are some of the main ways board book printing differs:
- Thicker Paperstock – Board books use thick paperboard instead of thin paper pages. This rigid material forms the basis of the book’s durability.
- Lamination – Individual pages are laminated with a protective plastic coating for extra durability and stain resistance. This also gives pages a glossy look.
- Specialized Binding – Pages can’t simply be glued together, so specialized case binding is used to assemble board book signatures. Reinforced endpapers provide further strength.
- Die-Cutting – Many board books utilize custom die-cut shapes or holes as interactive features. The entire book is die-cut for rounded corners.
- Small Print Runs – Economic digital printing of board books isn’t possible. Offset printing with specialized equipment is required, with typical minimum print runs between 1,000-2,000 units.
With key differences explained, let’s look at the complete board book printing process step-by-step.
How Are Board Books Printed: Step-By-Step Process
Printing a board book is a multi-stage process comprising design and pre-press, printing pages, binding, finishing, and shipping. Here’s an overview of each step:
1. Design and Pre-Press
The process begins with book design and content layout using publishing software such as Adobe InDesign. The layout should take into consideration limitations of the board book format – simple content and large illustrations work best.
With the design finalized, pre-press work prepares files for printing. This includes:
- Color correction and proofing
- Creating printing plates
- Die-making if special shapes will be cut
At this stage, downloadable templates provided by the printer ensure artwork aligns with production capabilities and has the correct margins and bleeds.
2. Print Pages
Board book pages get printed on large offset printing presses. Unlike digital printing which prints directly from files, offset printing involves several interim steps:
- Making Printing Plates – Thin aluminum plates are coated with a light-sensitive chemical layer and exposed to UV light. This cures and hardens the plates ready for printing.
- Mounting Plates on Press – Printing plates get fixed to plate cylinders on the printing press. There’s one cylinder for each color being printed.
- Running the Print Job – As paper feeds through the press, it rolls over the plate cylinders which apply ink. For full-color printing, the paper makes multiple passes – one for each color separation.
Specialized offset printing presses use registration systems to precisely align each color layer as they get applied to the paperboard.
Boards may get printed on one or both sides, depending on the layout design. Printed reels then move to the bindery for the next production phases.
3. Lamination
At this stage, printed boards go through a laminating machine. This applies a protective plastic polymer coating over the boards to enhance durability. Lamination also gives pages an attractive glossy finish.
There are a few laminate options:
- Gloss Lamination – High-gloss plastic coat for a shiny look
- Matt Lamination – Low-gloss coat for a smooth, subtle finish
Boards can pass through the laminator multiple times for thicker laminate layers if maximum durability is required.
4. Binding
Now laminated boards undergo specialized binding to assemble them into book format. There are two main binding options:
1. Case Binding
Case binding provides maximum strength and durability. It comprises several stages:
- Rounding/Backing – Individual boards get lightly bent using a rounding and backing machine. This pre-shapes boards for assembly.
- Edge Trimming – Boards also get precisely trimmed along the edges.
- Collating Signatures – Printed and laminated boards get grouped together into small book blocks called signatures. Each signature may consist of between 2-8 boards, depending on the size and thickness.
- Adhering to Cover – Signatures get precisely glued into the front and rear cover boards using strong suitable adhesive.
- Wrapping Reinforced Endsheets – The assembled book gets wrapped in durable reinforced endsheets for further strength.
2. Mechanical Binding
Some less complex board books undergo mechanical binding instead. This is quicker and more affordable but suits less complex layouts.
Mechanical binding involves stacking printed and laminated boards and then clamping them firmly together. Materials like sturdy gauze strips get tightly wound horizontally around boards to hold pages together. Durable reinforced endpapers also get added just like case binding.
5. Die-Cutting
If a board book design incorporates special custom shapes or holes as interactive elements, this happens at the die-cutting stage.
The assembled book blocks get precision die-cut using a hydraulic die-cutting press. This presses steel cutting blades through all book pages in one action, creating finished cut edges.
As part of die-cutting, books also get rounded corners cut for safety and durability.
6. Additional Finishing
Before completion, some additional finishing touches may enhance board books depending on requirements:
- Spot UV – A thick gloss varnish can get applied to specific areas for tactile and visual effects.
- Foil Stamping – Gold, silver and colored foil can provide eye-catching embellishments.
- Debossing – Indentations can add embossed textures for tactile interest.
These finishes add excitement, encouraging interaction with the books!
7. Packing and Shipping
Final steps involve careful packing to prevent damage and shipping to the author or nominated locations:
- Books get shrink-wrapped or bagged up individually.
- Books get packed into durable cardboard shipping cartons. Several may stack together on a wooden pallet for complex distribution plans involving warehouses and third-party logistics.
- After delivery to the required recipient address, it’s time to get selling and distributing the finished board books!
And that completes the board book printing production process from start to finish. While lengthy and detailed, these steps result in extremely durable, high quality board books perfect for infants and toddlers.
Key Specifications When Ordering Board Book Printing
Now that you understand the production process, here are the key specifications required for customizable board book printing:
1. Trim Size
Standard trim sizes for board books range from 5″ x 5″ up to 8″ x 8″. 6″ x 6″ is commonly used. Choose what’s easiest for little hands to hold.
2. Page Count
Ideal page lengths are 16, 24 or 32 pages. Ensure page counts are in multiples of 8 allowing pages to be divided into printer’s signatures.
3. Paper Weight
350gsm and 400gsm are common paper weights. Heavier stocks are more durable but increase thickness.
4. Binding Type
As outlined above, case binding delivers more durability than mechanical binding.
5. Print Finish
Gloss or matt laminate finishes provide protection. Interactive finishes like spot UV, foil stamping and embossing may also be selected.
6. Print Extras
Consider die-cut elements or specialty treatments if suitable. Rounded corners get cut as standard.
I hope this guide has provided lots of helpful insights into the magical process of transforming book files into durable, exciting board books! Let me know if you have any other questions.