Developments in Book Printing

72 Pages·2007·1.953 MB·English

by  Pira International Ltd, Hamish Mackenzie

Developments in Book Printing
Hamish Mackenzie
Published by
Pira International Ltd
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© Copyright
Pira International Ltd 2007
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Contents
List of tables v Digital printing inks 16
List of figures vi Future of book inks 17
4
Executive summary vii
1
Book preparation: prepress goes
Introduction 1 digital 19
Methodology 1 Quality assurance 19
2
Automation 19
Unified workflows 21
Collaborative workflows 21
Database-driven production 23
Market overview 3 Outlook 23
5
Print-to-sell 4
Sell-to-print 5
Key stakeholders 5
Publishers 6
Raw material suppliers 6 From offset to digital: book printing
Equipment suppliers 7 in transition 25
Printers 7 Offset lithography 25
Wholesalers and distributors 7 Elements 26
Retailers 8 Advantages 27
End customers 8 Disadvantages 28
Key trends 8 Recent innovations 28
3
Outlook 29
Digital printing 30
Types 30
Business models 33
Raw materials: book papers and Advantages 33
inks 11 Disadvantages 34
Book papers 11 Recent innovations 34
Cost 12 Outlook 34
6
Weight and size 12
Finish 13
Environmental factors 14
Future of book papers 14
Book printing inks 15 Book finishing: the modern post-press
Offset printing inks 16 process 37
Page iii © Copyright Pira International Ltd 2007
Developments in Book Printing
Contents
Cutting 37 Public digital libraries 54
Folding 37 Copyright issues 54
Stitching 37 Barriers 54
Perfect binding 39 Advantages of paper books 55
Hardcover binding 40 Advantages of e-books 56
Other post-press tasks 40 Commercial e-book readers 57
Outlook 41 Electronic paper 58
7 Outlook 59
9
On-demand printing: the coming
revolution 43 Lightning Source 61
Business models 44 Size and location 61
Technology 45 Capabilities 62
Cost benefits 46 Customers 62
Environmental benefits 47 Technology 63
Drivers 48 Future plans 63
Threats 49
Outlook 50
8
Futureshock: e-books, online
publishing and electronic paper 53
Publishers’ digital libraries 53
Page iv © Copyright Pira International Ltd 2007
List of tables
2.1 Key trends in book printing 8 6.1 Components of a saddle-stitching
4.1 Key elements of a DAM system 21 machine 38
4.2 Key elements of a collaborative 6.2 Production stages for perfect
softproofing system 22 binding 39
5.1 Offset printing in book 9.1 North America's top 10 book
production 26 manufacturers 61
5.2 Strengths and weaknesses of sheet- 9.2 Key facts about Lightning Source 61
fed offset presses 27 9.3 Two big customers of Lightning
5.3 Strengths and weaknesses of web-fed Source 62
offset presses 27
Page v © Copyright Pira International Ltd 2007
List of figures
2.1 Offset printing versus on-demand 5.3 HP Indigo 3050 digital press 32
printing 4 6.1 Post-press for a hardcover library
2.2 Stakeholders in the print-to-sell edition 40
model 5 7.1 The Espresso Book Machine 46
3.1 Finishes for book paper 13 8.1 The iLiad e-book reader 57
5.1 Timson T-48A ZMR non-stop web 8.2 The Readius e-book reader 58
press for short-run book printing 29
5.2 Xerox Nuvera 288 digital press for
books and manuals 31
Page vi © Copyright Pira International Ltd 2007
Executive summary
Book printing is still dominated by the offset lithographic process and the print-to-sell
publishing model, but a revolution is under way, driven by digital printing, automation,
self-publishing, internet bookselling, and the emerging sell-to-print model. Publishers
are used to estimating how many copies of a given title will sell, printing them and then
trying to sell them. Unfortunately, they are usually left with excess inventory, which then
has to be destroyed. And if a book is more popular than expected, they may not be able
to fulfil orders when demand is at its peak. This system wastes time, money and natural
resources; producing unsold books creates emissions and waste that needlessly pollute the
environment. Digitalisation has already speeded up all forms of book printing by replacing
much manual prepress with simpler software tools. Automated machinery is faster, has
better quality and is more integrated; it has significantly shortened book turnaround
times. But another revolution is about to happen and it could be even more fundamental.
The on-demand, sell-to-print book production model allows publishers to match
orders with the exact number of copies required by using digital printing services that can
produce fully bound books from a single machine in a matter of minutes. This style of
book printing is better for short runs and could not be used to produce a best-seller, but
most book sales come from short runs, so sell-to-print suits the likely future of the book
industry. Conventional book printers need to think seriously about whether to invest in
digital equipment for sell-to-print. This is particularly important as their existing business
is threatened by cheap competition from abroad. Increasing the volume of digital printing
and encouraging the use of recycled materials would also help book printers and their
customers meet environmental obligations and targets as green issues rise up the political
agenda. Sell-to-print is a threat to book wholesalers and could eliminate them from the
supply chain altogether. Retailers could even purchase on-demand printing machinery and
fulfil orders themselves.
Sell-to-print creates opportunities as well as challenges. On-demand printing makes it
quick and economical to produce out-of-stock or out-of-print titles in niche markets. Titles
that would never have been reissued under print-to-sell have gained a new lease of life
and make money for publishers and printers when customers buy them under sell-to-print.
The rise of self-publishing could open up a huge new market for book printing, as authors
bypass rejections from big publishers and take the easy route to their audience. Paper
books face competition from online publishing, portable electronic devices that store
hundreds of books, and flexible displays with the readability of real paper, but e-books
and paper books are likely to coexist for many decades. There are few certainties in this
rapidly evolving market, but stakeholders that do not adapt will have to fight for their
existence over the next 10–20 years or perhaps even sooner.
Page vii © Copyright Pira International Ltd 2007

1
Introduction
The book printing industry is dominated by a single printing technology – offset
lithography – and a single business model – print-to-sell, which results in many books
being overproduced and a significant amount of wasted time, money, energy and
resources. Digital printing technology allows on-demand book production in a sell-to-print
business model, and this new model is threatening the status quo. Other challenges, such
as low-cost printing in developing economies, environmental concerns, plus electronic
books and reading devices, are also changing the face of book production. This report
defines the established book production process and explains how disruptive technologies
and business models are creating threats and opportunities for all stakeholders, including
book printers, publishers, raw material manufacturers, wholesalers and retailers.
Methodology This report is based on information gathered from a variety of sources, including industry
journals and other specialist publications, academic papers, press releases, special reports,
websites, product brochures, and contact with stakeholders in the book printing industry.
The author particularly thanks David Taylor of Lightning Source Inc. and Morris Rosenthal
of Foner Books for their insight into on-demand book printing.
Page 1 © Copyright Pira International Ltd 2007