Need a Unique Binding Solution? Consider Cased-In
Wire-O™
By: Chris Eckhart, President, Eckhart & Company

For most book projects, the appropriate binding style falls into one of four categories: mechanical binding, perfect binding or saddle stitching. Each one has its particular set of strengths that need to match projects with a complementary end use. For example, a book that needs to lay flat will require mechanical binding, while a book that needs a printable spine and a sophisticated look will most likely be perfect bound.

Binding options are narrowed considerably for complex book projects that need a solution that combines several of these elements. Consider a book with these divergent requirements: layflat capabilities, a printable spine, a traditional look, and sturdy construction that will withstand frequent, long-term use. It's a tall order, but cased-in Wire-O™ binding can fill it (Wire-O is a trademark of James Burn International). I'll explain the many uses for cased-in Wire-O here, and provide tips on preparing your jobs for this versatile and attractive binding option.

Why Cased-in Wire-O?
Cased-in Wire-O is an attractive combination of a thick, wraparound cover with the layflat capabilities of versatile Wire-O binding. This allows it to possess characteristics of both perfect and mechanical binding styles, without compromising the advantages of either.

The durability of cased-in Wire-O makes it an ideal binding solution for books that will receive extended and repeated use, such as journals and instructional guides. It's sturdier than most adhesive-bound books because the weight of the book isn't concentrated in the bind itself. It's also sturdier than a standard Wire-O book because the cover isn't attached directly the binding elements. Books that will be featured in retail locations are also prime candidates for cased-in Wire-O thanks to the high visibility of a wraparound cover.

Production options are numerous for cased-in Wire-O binding. Books can be bound with wire up to 1 ¼", which is large enough for most applications. There are also plenty of cover options available on cased-in books. In addition to foldouts and die cut pockets, covers can be designed to contain everything from audio cassette and compact disc holders to pens, pencils and other small giveaways.

Easy as 1-2-3
Cased-in Wire-O production involves three stages, with the first two performed simultaneously. The first step is to Wire-O bind the book block. The majority of cased-in Wire-O books are bound using 3:1 wire (3 loops per linear inch), which provides superior strength for extensive use. Binding is performed just as it would be for any other split-back Wire-O book, except that covers are replaced by thick end sheets that will be mounted to the case. These paper end sheets should be on substantially thicker stock than the text to ensure a proper fit and long life.

The second step is to manufacture the case, which often involves mounting a laminated sheet to two pieces of board to form separate front and back covers. Printed, laminated covers are ideal for retail book applications that call for high-quality graphics and a glossy cover to maximize visibility. Die cuts, foldouts, foilstamping and embossing can all be performed to add creative and functional touches. Even cloth covers are possible if the application calls for a unique, high-end look.

The third step is to adhere the Wire-O book block to the case. The two end sheets are glued to the case, allowing the wire elements to move freely under the spine. The most common application calls for a "soft" spine with a rounded appearance, although the spine can be mounted to board to create a "hard", square spine.

This last step is where a quality finisher can really make a difference. A company that can produce cased-in books automatically can offer improved turnaround times and produce a more consistent product. For example, my company uses a Kolbus Compact casing system to produce cased-in Wire-O books. This machine holds the book on a metal "wing", where glue is applied to the end sheets and the case is attached to the book block in a single, automated process. This not only leads reduced turnaround times, but yields efficient, consistent production.

Planning and Production Tips
Cased-in Wire-O production requires the exchange of a great deal of information. Keep the following tips in mind to be sure your project goes smoothly:

Create a bulking dummy and take exact measurements - The thickness of a cased-in Wire-O book block is of paramount importance to the quality of the finished product. The case is measured and manufactured based on the bulk of the book block; if that measurement is off by even 1/16", the book won't sit properly in the case. Likewise, if changes are made to the book block after production begins, it will render the cases useless. To avoid surprises, send your finisher a bulking dummy prior to production, or let your finisher know the details of the stock you plan to use and they will create a bulking dummy for you.

In addition to exact bulk measurements, trim sizes and text margins should be measured carefully. An under- or over-sized book block will yield unsatisfactory results, so be sure trim sizes are accurate. As with any other mechanically-bound book, text and image margins should also be considered. For a book using 3:1 wire, leave at least a 3/8" margin from the spine edge to the punched holes to avoid punching into type.

Plan properly to avoid "fallout" - The weight of the end sheets in the bound book block determines the strength of the cased-in book. If the end sheets are too light, the book will "fall out" of the case, causing it to sag in the middle when the book is held by the cover. This can lead to the glued end sheets tearing from the case. The proper end sheet weight for your project is based on the weight and number of the text pages. Be sure to communicate all details of the book with your finisher to be sure the proper weight end sheets are specified.

Thick book? Complex project? Consult your finisher early - Books approaching the maximum wire size of 1 ¼" require a little more experience and communication to turn out exactly as planned. For example, a single end sheet that wraps around the wire elements for reinforcement may be preferable to separate end sheets in some applications. This can only be determined when your finisher is aware of all production details. Early communication with your finisher is essential for the overall success of any complex cased-in Wire-O book.

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Chris Eckhart's company, Eckhart & Company, is an Indianapolis, Indiana-based bindery specializing in mechanical binding, loose leaf manufacturing and information packaging. Chris can be reached at (800) 443-3791, or chriseckhart@eckhartandco.com. His partner and brother, Brent Eckhart, is past president of the Binding Industries Association International.