Layflat binding is a revolutionary technique which allows print to flow seamlessly across a double page spread. Books lay completely flat once opened, which allows the text and images to flow across pages without being interrupted by the joint of printed sections.
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Have you heard of the layflat book? In our opinion, this is one of the best-looking solutions in bookbinding available and for sure one that provides the highest user experience. The lay flat binding method is an increasingly popular choice as a style of finishing. Layflat books open completely flat across the centre fold without the pages closing when placed down on a table.
This solution means that photographs in particular can be run across both halves of the spread with no loss of visibility down the centre of the spine. This gives some exciting design options, including landscape formats that open to display panoramas. Moreover, as lay flat books are made using high quality photographic paper, the imagery within stands out beautifully, creating maximum impact. Lay flat binding is eminently suitable for corporate publications, coffee table books, art books, or product books – anywhere quality images and content are bound in books. Construction of lay flat books is simple, but comparatively time consuming compared to more conventional binding methods such as perfect binding or saddle-stitching. It starts with single-sided printed pages that are folded in half, then one blank side is glued to the opposing blank side of the next spread in the sequence, and so on until all the spreads are attached to form a block.
What is a Layflat Book? A lay flat book simply put is a type of book binding technique that lays completely flat when opened on a surface. When you open a lay flat book, there is no gap or gutter (the gutter of a book is the blank space where the left and right pages meet) between the pages. This means that you can create a book with seamless, high impact double-page spreads. Lay flat binding is an ideal solution for creating a lay flat photo book, luxury coffee table book, or showcasing landscape shots that are panoramic and require seamless uninterrupted printing. Lay flat is one of the most effective book binding types when it comes to visual storytelling.
Often, layflat books come with two cover options: Softcover book: A soft cover book offers seamless flat pages complete with a soft yet sophisticated cover. Perfectly flexible when reading and exploring a book's captivating content. Hardcover book: A hard cover book exudes luxury with its 2500mic hardback cover, a suitable fit for books that need to stand the test of time whilst featuring the same lay flat qualities as a soft cover book.
How are Lay Flat Books Printed? The lay flay book printing method is rather simple but takes time and dedication to perfect to achieve our signature high-quality product. The Printing Process Step 1: Pre-Press The books are complex, requiring true attention to detail. Before sending to print, will check the specifications in detail and prepare the design file for print. Step 2: Printing The design file will be sent down to the printing factory where skilled operators will begin printing the design onto the chosen paper stock. Here, the inner pages will be printed as well as the cover. Step 3: Embellishment and Lamination At this stage, if have opted for any embellishment or lamination on the book's cover, this will also be added. For lamination, it will be able to offer a range of solutions from matt to gloss. Step 4: Trimming Once the pages have been printed they are guillotined to ensure they're trimmed to the correct size required for the lay flat process, usually leave an extra 3mm as the books will be trimmed again to the specified size e.g. A5, after being bound. Step 5: Folding When the design has been printed, the folding process begins on the paper board folding machine, the printed sheets will be creased in the center before the folding.
When printing a layflat book, it's important to note that we only print lay flat books on certain stocks, like the paper board, due to the intricate drying process of the pages after gluing. Signatures and inner pages don't take into consideration your book cover as this is printed separately. Step 6: Gathering Once the pages have been folded they are then gathered in the correct order, ready to be duplexed together. The pages are collated on the signatures collecting machine.
The Binding Process Step 1: Duplexing The process of creating a lay flat book involves duplexing or glueing one folded sheet to the next, back to back to create the pages and overall book block. This is unlike perfect binding where the individual pages are glued directly into the spine. The last page of each signature is covered on one side with adhesive and glued to the first page of the next signature. This process is continued until all the signatures are joined. This means that the overall thickness of your book's pages will become double. Two 140gsm pages glued together will become 280gsm thick. For some lay flat books, using the PVC or grey board insert between two signatures, more thickness to ensure durability and quality.
Step 2: Pressure Once all of the pages have been duplexed and glued together, this creates what is known as a book block. A book block is all the collated pages of a book created before being bound or covered.
After all pages have been securely bonded, the book block will be sent into the flat pressing machine. Placed under pressure to help the glue bind with the pages, this helps to create a strong bind that can be opened and laid flat with ease once dry. Some hardcover layflat books need more decoration, such as the head and tail band fixing, then the head and tail band fixing machine will be used to process.
The Finishing Process Soft Cover With the finished book block glued, the cover can be added. the cover casing in process begins on the board book cover casing-in machine, the book block is cased into the softcover, then is expertly flat pressed and creased. For softcover books, once the glue is dry, the final book is then trimmed along three sides to ensure the final pages are neat and consistent on the three knives trimmer.
Hard Cover At this stage, if you have opted for a hardcover book, this is also the board book cover casing-in machine to thank. Once the glue is dry, the book block is then trimmed along three sides to ensure the final pages are neat and consistent before binding to the cover. The book block will be joined with the hardcover case by the board book cover casing-in machine.
The greyboard and cover are brought together using the hardcover case making machine, where the hardcover is created.
Normally, the board book block and the hardcover case often need to be the round corner, which needs the book block corner rounding trimmer and the hardcover case corner rounding machine to achieve.
The finished case or 'cover' is then fed into the board book cover casing-in machine along with your existing book block where the hardcover is then attached to the book block via the greyboard using glue. Endpapers are the first and last sheets of paper in a book and are what attach the book block to the cover.
Final Checks and Packing Once complete, the lay flat books will take time to check over to make sure they meet high standards. The finished layflat books will then be sent to be carefully packaged, normally by the heat shrink film to pack, or insert the plastic bags, and using the Cardboard Paper Shredding Machine to break down the material into a grid cut padding, to protect the layflat books, then ready to be collected by couriers and shipped to your business.
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Board Paper Folding Machine
Automatic Gathering Machine
Board Book Mounting and Pasting Production Line
Board Book Gluing Machine
Automatic Lay Flat Binding Machine
Digital Photo Book Making Machine
Board Book Stacking and Flat Pressing Machine
Two Way Pressing Machine
Semi Auto Book Block Head and Tail Band Fixing Machine
Digital Head Band Fixing Machine
Digital Three Knife Trimmer
High Speed Three Knife Trimmer
Board Book Cover Casing In Machine
Semi Auto Case Making Machine
Semi Auto Dual Stations Case Making Machine
Multifunctional Automatic Hardcover Case Making Machine
High Speed Hardcover Case Making Machine
Automatic Double Head Round Corner Cutting Machine
Double Head Book Block Round Corner Trimming Machine
Automatic High Speed Book Block Corner Rounding Trimmer
HX60R Automatic Hardcover Case Corner Rounding Machine
HX500CR Semi Auto Hardcover Book Case Corner Rounding Machine
Semi Auto Hardcover Casing In Machine
Cardboard Paper Shredding Machine
