Bindwel webinar discusses trends in small and micro print runs

Pallippuram Sajith, Managing Director and Suresh Nair, Technical Director, Impel Services (Bindwel – Stelda Group) started the webinar by saying that we should call this a collaborative learning session or seminar rather than a master class. We are still far from mastering the process of digital book printing in short runs.

He said that a mindset shift is needed from mastering the process of digital book printing in short runs to a co-learning approach. He discussed the evolution of the book printing and publishing industry, focusing on market opportunities, current trends and the do’s and don’ts of bookbinding in the digital age.

“Printers must understand customer needs and behavior patterns and become consultants in order to be successful together.” He also draws parallels to changes in other industries, such as the fashion and music industries, and emphasizes the trend toward personalization and inventory reduction.

Why short runs? Sajith explains: “The shift to digital platforms and e-commerce has significantly increased the demand for on-demand printing. Customers today expect faster, more flexible, faster and personalized solutions.”

Sajith noted that about 70% of books in the U.S. are distributed through e-commerce.

He also reflected on the emerging trend of on-demand book printing influencing the book publishing industry.

The self-publishing industry in India has witnessed remarkable growth. The share of self-publishing in the overall publishing industry has increased from 10-15% to 30-40%. This boom has opened up a wide range of opportunities for authors, including editing, printing and design options. The potential for self-publishing in regional languages ​​is particularly high.

“Customization has become a major trend, offering individuals a personalized reading experience. Overall, self-publishing has opened up new opportunities for authors and readers and encouraged innovation and creativity in the publishing industry,” he said.

He added that the rise in self-publishing has led to an increased demand for small and micro print runs. Citing the number of some self-publishing platforms, he said Notion Press has already published over 30,000 titles. Pothi puts the number at 20,000 and Blue Rose has around 15,000 titles.

“Customers today are looking for more personalized products,” said Sajith. “There is now a demand for customized learning materials. Educational institutions often require small quantities of customized textbooks or workbooks for specific courses, which is driving demand for small and micro runs.”

Publishers now offer online services to access specific chapters. This personalization also extends to creating customized workbooks for students’ individual needs, for example, to address their strengths and weaknesses in subjects such as math and languages. India’s vast educational infrastructure of 1.5 million schools and 265 million students offers ample opportunities for textbook personalization.

Sajith made a few more points. The importance of sustainability in short run printing is to minimize waste and avoid overprinting. He also emphasized on integrating data-driven printing with e-commerce and incorporating anti-piracy measures such as personalization. In addition, he emphasized on the importance of maintaining a list of available books without excess inventory through print on demand and direct delivery to the end user, especially in e-commerce. In addition, he mentioned the benefits of short run printing for corporate printing including materials, training manuals and branded items.

Now for the most important question. What is the difference between short runs and micro runs? And what is the one-book model? Sajith said short runs are between 50 and 1,000 copies. If the run is less than 50 copies, it is micro runs.

The one-book model is self-explanatory. You print just one title, with no waste at all. Sajith mentioned that not many printing houses do this, except maybe Repro and Manipal.

Sajith agreed that digital printing has a higher cost per copy. “But you have to look at 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, obsolescence risks and shipping costs.”

When changing jobs, it is important to remember that this can lead to longer set-up times and affect quality control, he said. Another important aspect is standardization, especially with regard to paper format collection and resources.

Citing some case studies, he said Pearson Education has a zero inventory model in many countries, while some publishers have adopted a book-on-demand system where books are produced and delivered based on incoming demand. Overall, the demand for customized printing and delivery solutions will continue to grow as personalized books become more popular.

He said offset printing is best for long runs as it ensures consistent quality and long durability. Digital printing is better for shorter runs, testing and market validation. A hybrid approach using both methods is common. For example, a mid-sized publisher might start with digital printing for a new book to evaluate the market and then switch to offset printing for the second run after positive feedback. This shows the wide range of opportunities 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, Impel Services, on bookbinding for digital printing.

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

He also emphasized the direction of the grain. “The direction of the grain is important,” he said. “In a perfect binding, the grain should run parallel to the spine. Cross grain can cause problems such as cracking and peeling.”

In addition, the ink application in the back area should be minimized to avoid problems with the hot melt adhesive.

According to Nair, the latest adhesive technology for bonding is based on polyolefin (PUR), which can handle a wider range of paper types compared to conventional EVA-based adhesives.

“Proper moisture control is key to avoiding uneven bonding and blowout. Bonding trials should be conducted to establish benchmarks for each paper grade,” he said, adding, “Spine preparation is critical. The goal is to maximize fiber exposure so the adhesive can bond effectively. Scoring the spine also helps.”

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

The key is careful handling of materials, processes and equipment to ensure high quality and consistent binding of digitally printed books.

In his concluding remarks, Sajith stressed the need for standardization of paper sizes, inks and binding processes to ensure consistent quality and efficiency. He also spoke about the importance of conducting binding trials and maintaining quality control measures.

Sajith also stressed the importance of developing a robust business model that includes software and virtual platforms for customer interaction and order management. He encouraged printers to position themselves as advisors and counselors to their customers and help them navigate the evolving print landscape.