PRODUCTION NOTES
The "Tropical Rainforest" Risk – Humidity Control
The Challenge
Production took place in August, during Shenzhen's peak humidity season. The instruction sheet explicitly warned: "Perform dehumidification treatment upon completion, strictly following QC standards."
Hardcover books are highly hygroscopic. If the paper and boards absorb excess moisture during production, the finished books will release it later in drier climates (shipping to US/EU), leading to severe cover warping, a fatal defect for luxury books.
Our Solution
Full-Process Dehumidification: We activated our "Dry Protocol." Semi-finished goods were kept in climate-controlled zones from cutting to sewing.
Moisture Content Reduction: Before final packing, all books underwent industrial dehumidification to forcibly lower moisture content to safe export levels (6-8%).
Moisture Barrier: Silica gel packets were inserted during shrink-wrapping, creating a sealed micro-climate for each unit.
Heart Surgery Before Deadline – Last-Minute Foil Change
The Challenge
On August 11th, right before mass production, the client issued a critical alert: "Cover text changed. Need to modify the back cover foil die."
This threatened to scrap prepped materials and delay the tight August 21st delivery.
Our Solution
- Modular Die Response: We retained the correct front cover/spine dies and rush-ordered only the new back cover plate.
- Flexible Scheduling: While waiting for the new die (24h window), we shifted resources to finish sewing and endpapering. Once the new die arrived, the casing-in line started immediately, ensuring zero downtime and hitting the delivery target.
"Packing Like Artwork" – Double-Box Protection
The Challenge
The order required a "Box-in-Box" logistics solution, with specific instructions to insert 336 molded pulp corner guards between the inner and outer cartons.
Any omission in this labor-intensive process would risk corner damage during ocean freight.
Our Solution
- Sandwich Cushioning Structure: We implemented a rigorous SOP: Inner Carton -> 8-Corner Pulp Suspension -> Outer Carton. This creates a physical buffer zone, isolating the books from external impacts.
- Custom US Palletization: We utilized US-standard pallets (9-block style) and optimized the stacking pattern for the specific split quantity, maximizing container efficiency.
