Paper over board is environmentally friendly and cost effective. From full colour litho printed sheets we mount and line onto board. We can give you full specifications and provide lay sheets for you to arrange the design, printing and lamination of the paper or KNOCKOUT PRINT can print them and we will transform them into the finished product. Any size of binder is possible, because our traditional binding methods usually require no special tooling.

 
THE TECHNICAL STUFF

You may supply us the printed and laminated sheets laid down to our specifications.
 
Generally, for binders, folders and slipcases, the outer wrap should be printed onto a 150gsm matt coated art paper. It should then be film laminated in either gloss or matt finish.

The sheets should be supplied flat and untrimmed, with all cut marks kept beyond the printed area (including the 20mm turn-ins on all 4 sides). Any bleeds should extend to the full extent of the turn-in. The grain of the paper should preferably be parallel to the longest side.

We can supply plain lining papers, or, if a printed lining is required it should be 170gsm with machine seal or 150gsm if laminated.

Our standard board thicknesses are 2mm for boxes and 2.2mm for binders, but we carry other thicknesses in stock.   

We can assist you by advising you of the sizes we would recommend for the product, given the sheet size to be housed within the binder and the total thickness of the contents.

Paper over board binders can be made in any size you wish, but most follow the same basic sizing rules. To determine the size of the front cover and spine, it is necessary to know the size of the largest sheets to be accommodated, and the total thickness of the contents.

The width of the front cover and the spine of the binder need to be large enough to accept the ring mechanism.  The spine measurement is not the same as the ring capacity.

The outer covering paper needs to be 40mm bigger than the board case, to wrap around the case with a 20mm turn-in on all 4 sides.

The lining paper typically is 10mm smaller than the board case, to leave a 5mm border all round.  If the outer covering print is to be a solid colour, the print should bleed beyond the turn-in area, so as to not show white paper on the inside of the finished case. 

Matt lamination onto large areas of dark print is not advisable as it is liable to show scuff marks easily.

The following table gives the suggested dimensions for a one piece case 'D' ring binder to accommodate an A4 portrait sheet, with allowance for a 15mm tab. (This is sufficient to also house a normal A4 polypocket).