Binding the inkjet future: Short-run book production in India

The demand for short-run book printing in India has grown significantly in recent years, driven by the rise of digital platforms and eCommerce. This shift caters to diverse needs across self-publishing, corporate manuals, and educational materials, with newer segments such as “self-publishing academic institutions” adding further momentum.

Straits Research shows India’s print-on-demand market is expected to grow at a compound annual growth rate (CAGR) of 27.8% between 2023 and 2031. However, P Sajith, managing director at Bindwel, argues that this projection might underestimate the sector’s potential. “Given the low base we are starting from, the actual growth might be much faster. Short runs of 50–1,000 copies and micro runs of fewer than 50 copies are becoming the norm,” he observes.

As the focus shifts towards customisation and on-demand production, the transition from traditional sheetfed printing to inkjet technology is accelerating. In all this, inkjet printing is being recognised for its ability to meet the demands of short-run printing. Sajith points out that “customisation is now a key driver, with inkjet making it easier to deliver personalised content.” He adds that the technology eliminates plate-making and set-up costs, which reduces expenses for small-batch production. Furthermore, print-on-demand capabilities mean there is no need to stockpile books, eliminating storage costs and the risk of waste from overproduction. “The faster turnarounds offered by inkjet align perfectly with the dynamic nature of today’s publishing industry,” Sajith notes.

Overcoming bookbinding challenges

Despite advancements in bookbinding techniques, the processes associated with short-run projects face distinct challenges. Traditional techniques are often ill-equipped to handle the variability in book sizes and formats required for short-run production. Frequent job changeovers can lead to inefficiencies, while higher wastage levels become particularly problematic for smaller runs. Also, there is the issue of integrity checks, such as ensuring the correct covers are paired with their respective book blocks. Sajith elaborates, “Imagine a short-run book printer managing 25 titles in a single day. If the binder takes 15–20 minutes to change from one job to another, that’s an entire shift lost to changeovers. Binding systems must evolve to enable changeovers in under a minute to keep pace with demand.”

Modern binding solutions are beginning to address these issues by offering greater integration with inkjet printing workflows. Advances now allow signatures to be processed as cut sheets or with minimal folding, streamlining binding operations. Enhanced automation ensures accurate job understanding and format alignment, reducing errors and downtime. According to Sajith, “The binding system—whether inline or offline—must be capable of adapting to the fast-paced requirements of short-run projects. The ability to seamlessly switch between jobs in minimal time is critical.”

Inkjet printing technology has made strides in improving its compatibility with bookbinding. High-resolution output, precision ink application, and improved compatibility with a range of substrates ensure that the prints are durable and vibrant, making them ideal for high-quality binding. “The reduction in consumables costs has also made inkjet printing more accessible and viable for many businesses,” Sajith notes.

When it comes to cost-effectiveness, inkjet technology holds an edge for runs under 1,000 copies due to its lower set-up costs and faster changeovers. However, offset printing remains more economical for larger volumes. Sajith recommends a hybrid approach, saying, “Combining inkjet for short runs with offset for high-volume projects allows publishers to optimise production costs while maintaining quality across various scales.”

The return on investment for adopting modern bookbinding solutions is another factor driving their adoption. Faster turnarounds, reduced waste, and lower inventory requirements translate into clear financial benefits. Additionally, the ability to customise products opens doors to niche markets such as self-publishing and educational institutions. “Investing in modern binding systems isn’t just about efficiency. It’s about creating new opportunities and staying competitive in a rapidly evolving market,” Sajith explains.

Emerging bookbinding technologies

With the increasing demand for short-run book printing in India, there is a growing need for systems that enable rapid transitions between different run lengths and automate adjustments for various book formats.

According to Sajith, advanced systems like Bindwel’s Freedom 2K and Insta One-Book models are specifically designed to address these requirements. “With these solutions, print service providers can seamlessly adapt to the fast-changing requirements of short-run and on-demand printing,” Sajith explains.

Bindwel’s Insta

While Bindwel is the only India-based manufacturer of bookbinding equipment for short-run and on-demand solutions globally, solutions from Horizon, Muller Martini, and Meccanotecnica are also available.

Sajith announces that Bindwel is set to introduce the Trimit 30C SRT, a new trimming system aimed at enhancing on-demand book production. He remarks that this represents a significant advancement in efficiency: “This solution will enable precise trimming of books on demand, thereby improving the workflow for inkjet-printed books.”

Bindwel’s Trimit 30C SRT

The integration of automation in these systems not only streamlines production but also enhances scalability. Sajith notes that Bindwel’s Freedom 2K is ideally suited for short runs starting from 10 copies, while the Insta model is tailored for micro runs, including one-off projects. “These machines are built with the future of short-run printing in mind, where flexibility and precision are paramount,” he adds.

Importance of quality and automation

While speed and adaptability are crucial, the quality of bookbinding remains a cornerstone for ensuring professional standards in short-run printing. Sajith highlights the role of careful planning in maintaining quality, emphasising factors like grain direction, adhesive strength, and precision trimming. “The grain direction should always be parallel to the spine for both the inside pages and the cover to prevent warping,” he explains. Additionally, new-generation adhesives such as PO [full form] and polyurethane reactive (PUR) grades provide the durability required for modern binding.

Precision trimming is another critical aspect, especially when dealing with varied formats. Sajith points out that automated systems like Bindwel’s Trimit 30C SRT and Freedom 2K ensure consistency in spine preparation and adhesive application, which are essential for maintaining a professional finish. “Our technology is designed to integrate seamlessly with digital workflows, making it easier to meet the exacting standards of short-run and on-demand printing,” he says.

Automation also plays a pivotal role in addressing the growing demand for customisation. Features like quick job changeovers, QR code integration for personalised orders, and high-speed binding are key to meeting the requirements of short-run projects. “Automation is no longer a luxury; it’s a necessity,” Sajith emphasises. “With Bindwel’s Insta model, for instance, micro runs and one-off books can be produced efficiently without compromising on quality.”

Team Bindwel

From five to 5,000 copies

Bindwel’s Freedom 2K stands out as a versatile solution for short-run printers, offering seamless transitions across run lengths ranging from as few as five copies to as many as 5,000. According to Sajith, advanced automation makes this capability possible, including job-switching and size adjustments. “The Freedom 2K minimises downtime while supporting diverse project requirements, which is crucial for short-run printers,” he explains. The system also includes a thickness measurement device, providing an additional layer of quality assurance by detecting variations in paper bulk or GSM. Sajith adds, “This feature complements the metadata checks, ensuring precision and consistency.”

The machine is already operational in two leading Indian print facilities, SAP Print Solutions in Mumbai and Saurabh Printopack in Noida. “At SAP, the Freedom 2K handles loose leaves, while at Saurabh, it processes folded signatures, showcasing its adaptability across different workflows,” Sajith notes.

For micro runs and highly personalised projects, Bindwel’s Insta One-Book model offers unparalleled flexibility. Capable of producing up to 1,000 books per hour, each uniquely customised, the Insta integrates seamlessly with modern inkjet workflows. Sajith highlights the use of QR code reading for both the book block and the cover, ensuring accuracy and efficiency. “This capability makes Insta an ideal solution for on-demand printing, where every book can be different,” he says.

Sustainability and hybrid production

Bindwel’s innovations are not limited to production efficiency but align with the industry’s growing focus on sustainability and cost optimisation. The Trimit 30C Freedom SRT exemplifies this commitment with its adaptive knife movement and precision cutting, which reduce errors and waste. “Features like these are critical for maintaining a professional finish in short and micro runs while minimising material wastage,” Sajith explains.

Bindwel also promotes a hybrid production model, combining offset printing for high-demand titles with digital solutions for niche and short-run projects. Sajith underscores the advantages of this approach, saying, “Our hybrid model optimises costs and minimises waste while meeting the diverse needs of Indian publishers and self-publishers. The Freedom 2K, paired with the Trimit 30C SRT trimmer, is ideally suited for such applications.”

Sustainability remains a key focus for Bindwel, with solutions designed to reduce overproduction and optimise resource usage. Machines like the Insta and Freedom 2K enable just-in-time production, helping minimise inventory holding costs and material waste. Sajith concludes, “Our approach ensures that only the required quantity is printed and bound, contributing to both environmental goals and operational efficiency.”

With the evolution of the Indian printing industry, Bindwel’s bookbinding technologies are set to revolutionise the sector by providing scalable, sustainable, and affordable solutions that meet the needs of contemporary publishing.