BOOK SPECIFICATION
Format · Extent · Binding · Orientation
304.8 × 304.8 mm · 240 pages + 8 pages endpapers · Section-sewn square-spine hardcover · Square
COVER
Material · GSM · Board · Printing · Finishing
Material: Coated art paper · GSM: 157 gsm · Board: 3.5 mm greyboard · Printing: CMYK offset · Finishing: Matte lamination, spot gloss UV varnish
TEXT BLOCK
Paper · GSM · Color · Printing Method
Paper: Matte coated art paper · GSM: 157 gsm · Color: CMYK + spot color on selected pages · Printing Method: Sheet-fed offset printing, selective varnishing
ENDPAPERS
Material · GSM · Printing · Attachment
Material: Uncoated offset paper · GSM: 180 gsm · Printing: PMS 534, oil-based matte varnish · Attachment: Glued endpapers
OTHER COMPONENTS
Dust Jacket · Slipcase · Inserts · Edges
Dust Jacket: 157 gsm coated art paper, CMYK + 2 spot colors, matte lamination, spot gloss UV, 120 mm flaps · Headbands: Grey-blue fabric
PRODUCTION NOTES
Challenge 1: Precise Tonal Matching Against Historical Archival Proofs
The Challenge
As a reprint of a large-format wildlife photography monograph, maintaining exact chromatic fidelity—specifically the subtle greyscale gradations and high-contrast skin textures of wild elephants—against physical master proofs from prior press runs was critical.
Our Solution
Implemented high-precision stochastic screening (FM15u screening curves) for the interior text signatures. Press operators performed continuous spectrophotometric color matching against physical target sheets, applying targeted spot varnishes and additional spot gray passes (signatures 6 & 7) to achieve exact tonal depth.
Challenge 2: Multi-Process Finishing Alignment on Large-Format Covers and Dust Jackets
The Challenge
Registering localized spot gloss UV over specialized matt lamination across expansive 304.8mm × 304.8mm covers and 120mm jacket flaps requires extreme mechanical precision. Minor misalignments on metallic spot inks (PMS 877C) or glossy accents can ruin the visual presentation.
Our Solution
Executed dedicated pre-production lamination adhesion tests and utilized high-density 120T silk screen meshes for localized UV application. Precise dual-creasing on jacket flaps ensured crisp folding contours without film cracking or graphic misalignment.
Challenge 3: Dual-Pass Varnish Application on Heavyweight Custom Endpapers
The Challenge
Printing custom PMS 534U spot ink over 180g woodfree stock requires heavy ink saturation, which risks ink set-off or surface dulling if not sealed correctly.
Our Solution
Engineered a double-pass oil-based matt varnish workflow. The first varnish pass was applied inline alongside the spot color, followed by a complete drying cycle before applying the secondary protective varnish coat. This guaranteed deep, scuff-free color saturation across the endpapers.