Category Archives: Uncategorized
Circumstance by Formento & Formento
In 2013, French publishers, Yellowkorner began a very special book project with Pacom:
Formento & Formento.
Formento & Formento is a husband and wife team: BJ and Richeille Formento. They specialize in very high end art quality photography that has been said to have a style similar to “David Lynch and Hopperesque landscapes”. For them, this was their first book to be published and by working with Yellowkorner, they were planning something very special.
In terms of books projects, this was definitely not your ordinary project; Circumstance is a book that has very unique characteristics. It required Yellowkorner to find a printer that could provide tight quality control and a strict attention to detail.
The main hurdle on producing the book was with regards to the book’s size, specifically, 395mm in width.
What that meant is the book required a binding size that well exceeds the maximum bindery size of most binding manufacturing systems. Most facilities have maximum collating size of 320mm wide, book binding of 305mm wide, and automatic sewing machines of 320mm wide.
The book contains high quality photographs taken by Formento and Formento. The size and number of pages of this photography book, meant there was a need for a solid binding, something that could last for ages. The size of the book made this feat to seem impossible for most printers to produce. In fact, the size of the book is larger than the machinery at Pacom as well, however after much research and careful consideration, Pacom was chosen as the printer and binder to take on this project.
The solution was perhaps in some ways seemingly simple but yet in today’s world of machinery, quite unusual. Pacom decided they must do most of the processes by hand. From collating to sewing, to binding, to casing, each book went through a very intensive manual labor process.
To make a book, to keep a high level of consistency, and even more so, a book of this size and weight, it requires a special focus on the way it is bound. The binding is so incredibly solid. (Normally hard cover books we normally don’t paste the back of the book block to the spine. but we pasted to the spine. normally we did not doing this because it limits the books ability to open, but because of the width of the book it opens well and still holds very sturdy.)
Even the special casing that the book comes in was hand made.
60 signatures in all. 2300 books were created. And the results were extraordinary.
Inspecting each book in a row, it would be hard to see differences in the production. That is, with one exception: as is the case with all YellowKorner books, Circumstance was to be a limited signed edition. Therefore Bj AND Richeille Formento came to the Pacom factory during printing and personally signed and numbered each front page of all 2300 books. This was a project of love.
The slip case, is a wonderful piece all by itself. The client stressed that the cover material be of a very special color. Therefore, Pacom worked very closely with the Korean paper company, Dong-A, to specially custom order the cover material to match the sample perfectly.
The case also features metallic foil stamping by General Roll Leaf, a United States foil company. Pacom’s ability to locate the right sources worldwide was important in this situation.
For Formento and Formento, it was their first trip to Korea. Being that this was their first published book, they wanted to be very careful about the ink densities. Standard line screen is 175lpi, but Circumstance was printed at 200lpi. Also, black density was increased from 1.8 to 2.3. In order to be careful that the ink would not setoff, printed sheets were stacked much lower after printing to dry. (Printing was not that difficult but we had to increase the ink density from 1.8 to black density of 2.3 to 2.4. We had to pay much attention to the setoff (rubbing of ink). That was the main issue of the binding because the ink density was so strong.)
Custom paper was order due to the size characteristics. Pacom continued to work towards paper savings and cost savings while keeping the quality top notch.
They spent five days for the press check, and by the last day, they were only half way through. They left a bit concerned that the color matching might falter, but later after seeing the final book commented how impressed they were with the job the pressman did without them there.
Shipping: the weight of the book was such that only two copies would be put in each case. With the main book went to France, 150 went to the photographer in Massachusetts.
Reviews were tremendous, both from the publisher and photographer, and their clients as well. For Pacom, finding the solutions for all of the technical hurdles made this a very memorable and satisfying project.
Busch Punching Machine
When cutting book blocks into non standard designs, usually die cut machines are used. This however creates a non uniform stack. The Busch Punching machine can solve this issue by it’s ability to cut through multiple pages at the same time.
The rectangular pre-cut stacks are pressed through the cutting die using hydraulic pressure; at the same time they are pressed against a pneumatic driven counter pressure matrix, which is located in the cutting die. The material is straightened and pressed before the much stronger hydraulic pressure overcomes the pneumatic pressure and presses the stacks through the cutting die.
The outcome is a highly precise punched result, something that cannot be achieved by other systems. The output is lower, but the system is used when extreme accuracy is required and when modern materials are punched.
|Max. die-cut size||330 mm x 380 mm|
|Min. die-cut size||80 mm x 100 mm|
|Max. stack height |
(height of cutting die 90 mm)
|Max. diameter for circular products||365 mm|
|Die-cutting pressure||11.7 kg|
|Die-cutting strokes max.||9 p/min|
|Max. machine output|
(for works without counter-pressure feeding 1000 sheets, label paper 80 gsm)
Create wonderful things, be good, have fun.
For over 10 years, Pacom Korea has been one of the leading suppliers for Klutz Press of Palo Alto, California. Klutz Press is the makers of fine children’s activity books and craft books.
Klutz is a publishing company started in Palo Alto, California in 1977 and acquired by Scholastic Inc. in 2002. The first Klutz book was a how-to guide titled Juggling for the Complete Klutz, which came provided with juggling beanbags attached in a mesh bag. The book was created by three friends who graduated from Stanford University: Darrell Lorentzen, John Cassidy, and B.C. Rim beaux. Since then the company has continued to specialize in activity-driven books sold along with other items needed for the activity. Not all the books are about developing a skill; there has also been a geography book containing, among other physical attachments, packets of rice corresponding to the average daily caloric intake among the poorest people of the world. Many of their books are spiral bound and teach various crafts. The items needed are usually included with the book, e.g. the juggling guide. The Klutz credo is: Create wonderful things, be good, have fun.
Transforming Lives Together
Pacom Korea has been one of the leading suppliers for Cook Communications.
David C. Cook is a nonprofit Christian publisher based in Colorado Springs, Colorado. It was established in 1875 by David Caleb Cook in Chicago, IL and publishes fiction and nonfiction books as well as over 10 lines of Sunday School Curriculum. It uses its profits for global ministry. For many years it published a Christian comic book, Sunday Pix, with stories about the adventures of Christian heroes in many different eras and in many parts of the world.
Pacom was awarded by the Korean Intellectual Property Office patent #: 10-1321502 for it’s invention of the “System for inserting a calendar pad into a calendar”. Normally a manual labor task, Pacom has created a method for automated insertion.
If you can’t hear the sound of the Notch Binding machine, then it must be a holiday at Pacom. Otherwise, when they line up shoulder to shoulder, they make one of the longest teams at Pacom.
Mr. Jung Dae-Sung is Section Chief. You can recognize him even from far away because of his colorful hair. He’s known for always take care his staff well. It’s a tight team, they work together in unison. In fact, we asked each person for a small interesting piece of information. Here’s what we found out:
Mr. Lee Sun-Jae, Deputy Section Chief, is famous for his diligence, not only at work, but home as well.
Mr. Wan-Su Kim, Deputy Section Chief, as half of a working married couple, sets an example for excellent housework.
Mr. Joo-il Kim, Chief of Machines, is always repairing machines.
Mr. Yun-il Jo is the proud father of his son who just married.
Mr. Suk-bong Han is known for his calligraphy and handwriting abilities.
Mr. Lee Hwa-Ryong is not originally from South Korea.
Mr. Chan-Sung Jung is always neat with short hair.
Ms. Yun-Sun Jung is beautiful like her name.
Ms. Hye-Ja Kim always smiles bright and has a positive nature.
Mr. Sun-Wol Huh is always treating beverages to other coworkers during break time.
Ms. Chan-ok Jung is famous for her powerful laugh.
Ms. Se-ju Yang enjoys climbing mountains with her husband during holidays.
Everyone in this team works hard and they also love to join group activities with Mr. Jung Dae-Sung, Section Chief, in the lead.