BOOK SPECIFICATION
Format · Extent · Binding · Orientation
254 × 304.8 mm · 288 pages+ 8 pages endpapers · Section-sewn square-spine hardcover · Portrait
COVER
Material · GSM · Board · Printing · Finishing
Material: Coated art paper FSC Mix Credit · GSM: 157 gsm · Board: 2.5 mm greyboard FSC Recycled 100% · Printing: 5 colors (CMYK + PMS 359C) single-sided · Finishing: Single-sided gloss lamination, spot matte UV, gloss silver foil stamping SA-910
TEXT BLOCK
Paper · GSM · Color · Printing Method
Paper: Refer to text block job ticket SZPM26050280 · GSM: Refer to text block job ticket SZPM26050280 · Color: Refer to text block job ticket SZPM26050280 · Printing Method: Refer to text block job ticket SZPM26050280
ENDPAPERS
Material · GSM · Printing · Attachment
Material: Uncoated woodfree paper FSC Mix · GSM: 140 gsm · Printing: PMS 359U + C + M double-sided, mixed varnish · Attachment: Glued endpapers
OTHER COMPONENTS
Headbands · Packaging
Headbands: GF190 · Packaging: Individual shrink wrap, export cartons
PRODUCTION NOTES
Challenge 1: Color Uniformity and Ink Adhesion Across Complex Surface Finishes
The Challenge
Applying a combination of full-surface gloss lamination, selective spot matte UV coating, and SA-910 bright silver foil stamping over a vibrant four-color plus PMS 359C spot ink layer creates risks of ink lifting, edge cracking, or register shifting during high-speed casing-in.
Our Solution
Calibrated tight multi-pass registration for the 120T screen printing phase after gloss film lamination. Controlled thermal impression parameters during silver foil stamping to secure permanent adhesion on film-coated substrates while preserving sharp graphic outlines across all 2,250 production units.
Challenge 2: Color Consistency Between Endpapers and Coated Text Components
The Challenge
Ensuring seamless visual alignment of Pantone 359 spot color across two completely different substrates—140g uncoated offset paper for endpapers and coated art paper for exterior wrap—requires precise color management to prevent batch hue shifts.
Our Solution
Formulated custom spot ink ratios (Pantone 359 U/C) tailored to the absorption profiles of both uncoated bird offset and coated stocks. Applied a inline protective hybrid varnish (3:1 blend) on uncoated endpapers to match the surface sheen and tactile density of the main book block.
Challenge 3: High-Stress Structural Casing and Multi-Destination Export Protection
The Challenge
Casing a heavy-gauge 2.5mm binder's board with multi-treated laminated wrap requires robust spine squareness and edge adhesion. Furthermore, fulfilling complex international logistics—split across multiple air and sea freight shipments—demands transit-proof packaging.
Our Solution
Utilized automated casing-in lines equipped with GF190 headbands to secure the spine block. Implemented customized export packaging featuring individual shrink-wrapping, corner guards, inner liner boards, and reinforced double-wall cartons to comply with global shipping requirements.