BOOK SPECIFICATION
Format · Extent · Binding · Orientation
215 × 275 mm · 312 pages + 8 pages endpapers · Square-spine semi-casebound hardcover · Portrait
COVER
Material · GSM · Board · Printing · Finishing
Material: Coated card · GSM: 350 gsm · Board: 250 gsm white card reinforcement at spine and inside cover areas · Printing: CMYK H-UV offset printing · Finishing: Matte lamination, raised spot gloss UV, metallic foil stamping, embossing, 150 mm flaps, 2 mm head and tail overhang
TEXT BLOCK
Paper · GSM · Color · Printing Method
Paper: Matte coated art paper · GSM: 128 gsm · Color: CMYK · Printing Method: Sheet-fed offset printing · Binding: Section-sewn with water-based adhesive for lay-flat opening
ENDPAPERS
Material · GSM · Printing · Attachment
Material: Uncoated paper · GSM: 160 gsm · Printing: CMYK with protective matte varnish · Attachment: Glued endpapers; rear endpaper reinforced with 250 gsm white card
OTHER COMPONENTS
Dust Jacket · Slipcase · Inserts · Edges
Headbands: Dark red fabric · Ribbon: Red grosgrain ribbon, 3/8 in wide, 380 mm total length · Edges: No special edge finishing specified · Packaging: Packed in export cartons, no individual shrink-wrapping
PRODUCTION NOTES
Challenge 1: Continuous Cross-Flap Image Alignment with Reinforced Flexi-Cover Construction
The Challenge
The publication requires precise graphic alignment between the front/back cover inner flaps (150mm) and the adjoining front/rear endpapers. Aligning continuous photographic artwork across a multi-layer flexi-cover structure—which features 250g cardstock reinforcement board, 150mm wrap-around flaps, and a 2mm overhang—introduces severe misregistration risks during manual casing-in and final three-knife trimming.
Our Solution
Implement custom die-cutting registration marks and pre-folding score lines specifically calculated for the 250g lining card thickness. Utilize high-precision manual alignment fixtures during casing-in, accompanied by 100% visual inspection during three-edge trimming to guarantee flawless seam continuity between the inner flaps and endpapers.
Challenge 2: Heavy-Duty 312-Page Lay-Flat Binding and Edge Reinforcement for Field Use
The Challenge
The 1,418g, 312-page Kgalagadi Self-Drive Revised Edition requires exceptional binding strength while maintaining seamless lay-flat opening. Standard EVA hot-melt adhesives can crack under frequent flat-opening, while heavy handling risks tearing the rear cover assembly where the 150mm flap meets the text block.
Our Solution
Deploy high-flexibility water-based cold-glue binding paired with precision thread sewing across 20 signatures (312 pages) to ensure complete 180-degree lay-flat performance. Laminated a 250g white board insert onto the rear endpaper (#4 sheet) to reinforce spine tension and eliminate cover deformation during intensive outdoor usage.
Challenge 3: Multi-Pass Surface Finishing and Dehumidification Control on 350g Cover Stock
The Challenge
Executing single-sided matte lamination, high-build spot UV (77T mesh), rose gold hot foil stamping, and registering foil-to-emboss on 350g heavy C1S art card creates extreme thermal stress. Post-press heat exposure and moisture loss can cause severe cover warping or edge curling on flexi-bound books with 150mm wide inner flaps.
Our Solution
Perform strict force-drying and dehumidification pause cycles after lamination and HUV press runs to stabilize paper moisture before foil stamping and embossing. Utilize temperature-calibrated foil dies for KA-205 rose bright gold stamping, ensuring structural flatness across the 350g cover before spine-board lining.