Saddle Stitching: This is the cheaper version of binding a magazine and ideally, for good cost effectiveness, your magazine should be a maximum of 64 pages plus 4 page cover. We can saddle stitch magazines with more pages, but the cost increases disproportionately due to a pre-gather being necessary. There is a limit on the thickness of a magazine that can be saddle stitched which is defined by the number of pages and the weight of paper being used. Our Sales Administrator or your Production Controller will advise you.
The 8 page sections (sometimes 4 page sections) are gathered together on our high tech Muller Saddle Stitching line - which has 8 section stations plus a cover feeder - and two wire stitches are inserted into the spine to hold the whole content together. It is then trimmed on the three open edges via a three knife trimmer to the required size. As the sections are gathered together they are automatically scanned to ensure the correct sections are in the correct order, the completed magazine is then automatically measured to ensure that no section is missing.
Perfect Binding: This method of binding your magazine provides the square back look and is considered the better image for high quality publications. It is more expensive than saddle stitching, but not if the pagination is more than 64 pages plus cover. For good cost effectiveness, this method of binding should be a maximum of 112 pages plus 4 page cover. We can perfect bind magazines with more pages but the cost increases disproportionately due to a pre-gather being necessary. The cover material on perfect bound magazines needs to be at least 150gsm.
The 8 page sections (sometimes 4 page sections) are gathered together on our high tech Muller Perfect Binding line, which has 14 section stations plus a cover feeder. The sections are gathered together and clamped, then the spine is sawn off and glue is applied. The clamped and glued sections are then presented into the waiting cover to be re-clamped. They are then released and travel along a conveyor in order to give the fast drying glue time to harden before going through the three knife trimmer to trim the magazine to size on the three open edges.
The finished magazines from either the Saddle Stitching binding line or the Perfect Binding line, can then either go through a polythene shrink wrap tunnel to provide shrunk wrapped bundles, or be placed into cartons, or left loose and strapped onto pallets.
Bound-in inserts can be incorporated into the magazine at the binding stage, as long as the specifications of size and style are cleared with our Operations Director beforehand. However, a section station will be used for a bound-in insert and this will therefore reduce the total pagination of the publication.