Bindwel webinar discusses trends in short-, micro-run book printing

Pallippuram Sajith, managing director, and Suresh Nair, technical director of Impel Services (Bindwel - Stelda Group) began the webinar by saying that we should refer to this as a co-learning session or seminar, instead of a master class. We are a long way from mastering the process of short-run digital book printing. 

He said there is a need for a shift in mindset from mastering the process of short-run digital book printing to embracing a co-learning approach. He discussed the evolving nature of the book printing and publishing industry, focusing on market opportunities, current trends, and the dos and don'ts of bookbinding in the digital era. 

“Book printers need to understand customer requirements and behavioural patterns, and become advisors and consultants to achieve mutual success. He also draws parallels with the transformation seen in other industries, such as fashion and music, emphasising the trend towards personalisation and reduced inventories.

Why short-run? Sajith explained, “The shift towards digital platforms and eCommerce has significantly increased the demand for on-demand printing. Customers now expect faster, flexible, fast and personalised solutions.”

Sajith observed that that around 70% of books in the USA are distributed through eCommerce.

He also reflected on the evolving trend of on-demand book printing's influence on the book publishing industry.

The self-publishing industry in India has seen remarkable growth, with an increase from 10-15% to 30-40% of trade publishing attributed to self-publishing. This surge has led to diverse opportunities for authors, including options for editing, printing, and design. Notably, there is a significant potential for regional language self-publishing. 

“Customisation has become a key trend, offering personalised reading experiences for individuals. Overall, self-publishing has brought about new avenues for authors and readers, fostering innovation and creativity in the publishing industry,” he said.

He added that the rise of self-publishing has led to the increased demand for both short- and mirco-run printing. Sharing the number of some self-publishing platforms, he said, Notion Press has already published over 30,000 titles. Pothi, the number is 20,000 and for Blue Rose it is about 15,000 titles. 

“Customers are now seeking more personalised products,” Sajith said. “There is now a demand for customised learning materials. Education institutes often require small quantities of customised textbooks or workbooks for specific courses, driving the demand for short and micro-runs.”

Publishers now offer online services for specific chapter access. This personalisation extends to creating tailor-made workbooks for individual student needs, such as addressing their strengths and weaknesses in subjects like math and language. India's vast education infrastructure of 1.5 million schools and 265 million students provides a significant opportunity for customising textbooks.

Sajith shared some additional points. The importance of sustainability in short-run printing is to minimise waste and prevent overprinting. It also highlights the integration of data-driven printing with eCommerce and the incorporation of anti-piracy measures, such as personalisation. Furthermore, it emphasised the significance of maintaining a list of available books without excessive inventory through printing on demand and direct supply to the end user, particularly in eCommerce. Additionally, it mentioned the benefits of short-run printing for corporate printing, including materials, training manuals, and branded merchandise.

Now, the most important question. What is the difference between short-run and micro-run books? And what is the one-book model? Sajith said short-runs include a run length of between 50 to 1,000 copies. If the run length goes to less than 50 copies, it’s micro-run. 

The one-book model is self-explanatory, where you print just one title, without any wastage. Sajith mentioned that not many printers are doing it, except perhaps Repro and Manipal.

Sajith agreed that in digital printing, per copy cost is higher. “But you need to see the cost in terms of the entire value chain,” he said. “It’s important to consider the total cost of ownership, which includes inventory costs, warehousing, obsoletion risks, and shipping costs.” 

He said when it comes to job changeovers, it’s important to note that they can lead to longer setup times and affect quality control. Another important aspect is standardisation, especially regarding paper format collection and resources. 

Looking at some case studies, he said Pearson Education had a zero-inventory model in many countries, while some publishers adopted a books-on-demand system, producing and supplying books as per the incoming demand. Overall, with personalised books becoming more popular, the demand for customised printing and supply solutions will continue to grow.

He said offset printing is best for large print runs, ensuring consistent quality and long shelf life. Digital printing is more suitable for smaller runs, testing, and market validation. A hybrid approach utilising both methods is common. For instance, a mid-sized publisher might start with digital printing for a new book to assess the market, then transition to offset printing for the second edition after positive feedback. This demonstrates the diverse possibilities in the book printing and publishing value chain in today's digital world.

Sajith’s presentation was followed by a presentation by Suresh Nair, technical director of Impel Services on bookbinding for digital printing.

Nair said, “Paper selection is crucial for digital printing. The commonly used paper is 60 or 80-gsm. However, highly coated papers can be challenging. It's important to test the paper before binding.

He also stressed grain direction. “Grain direction is important,” he said. “For perfect binding, the grain should be parallel to the spine. Cross-grain can lead to issues like cracking and peeling.”

Also, ink coverage near the spine should be minimised to avoid issues with the hotmelt adhesive.

Nair said the latest binding adhesive technology is polyolefin-based (PUR), which can handle a wider range of paper types compared to traditional EVA-based adhesives.

“Proper moisture control is the key to avoiding uneven binding and blow-outs. Binding trials should be conducted to establish benchmarks for each paper type, he said, adding, “Spine preparation is critical. The goal is to maximise fibre exposure for the adhesive to bind effectively. Notching the spine also helps.”

He also stressed that equipment selection is important. “Digital printing requires faster job changeovers, thickness measurement devices, and precise spine preparation and trimming capabilities,” he said. 

The key is to carefully manage the materials, processes and equipment to ensure high-quality, consistent binding for digitally printed books.

In his concluding remarks, Sajith stressed the need for standardisation in paper formats, inks, and binding processes to ensure consistent quality and efficiency. He also discussed the importance of conducting binding trials and maintaining quality control measures.

Sajith also emphasised the significance of developing a robust business model, including software and virtual platforms for customer interaction and order management. He encouraged printers to position themselves as consultants and advisors to their customers, helping them navigate the evolving printing landscape.