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Insert Specifications

• Inserts for Saddle Stitched Books
• Inserts for Perfect Bound Books
• Correct Quantity of Inserts to Furnish
• Packaging & Shipping Requirements
• Packaging of Inserts or Cartons on Pallets
• Pallet Requirements

Note: All Inserts must be approved by the Bindery Manager for insertion

• INSERTS FOR SADDLE STITCHED BOOKS
  • Inserts Through a Regular Saddle Stitcher Pocket (Untrimmed Size):
    1. Width: Side of insert with binding lap
       • Minimum: 5"
       • Maximum: 12"
       • Short side of insert minimum 3 1/2"
    2. Depth:
       • Minimum: 4 1/4"
       • Maximum: 19"
    3. Minimum stock weight:
       • 2-page insert: 60 lb.
       • 4-page insert 50 lb.
       • 8-page insert: 40 lb.
    4. Two-page inserts, with no binding tab, require tipping to press signature (see Tip-On Specifications).
    5. Folded inserts must be provided with a 3/8. binding lap. (See Lap Definition to determine whether the lap should be high or low folio.) If in doubt, please check with your Account Executive. If inserts have less than a 3/8. lap, or must be furnished with incorrect lap, please check with your Account Executive.
    6. Inserts can not be wider or deeper than press signatures. Please check with your CSR.
    7. Inserts for digest-size books must be furnished two deep with provision for both head and foot trim, as well as trim out between 2-up books (1/4. for saddle stitch; 3/8. for perfect bound). If you have questions, please check with your Account Executive.
    8. Inserts count as a pocket unless it is tipped onto a signature.
    9. Insert with a reverse lap can be bound at an additional charge, as long as the lap is 3/8. minimum or 5/8. maximum in length.
    10. Laps greater than 5/8. cause a Slow Down at an additional charge. Please consult with your CSR.
    11. Inserts with less than a 3/8. lap can be inserted at an additional cost. Check with your CSR.
    12. No double or single gatefold in center of book unless both head and foot of gates are glue tacked.
    13. Inserts requiring vacuum feeding:
        • Width: Minimum 7 1/2"; maximum 16"
        • Depth: Minimum 7"; maximum 16"
  • Specifications for Flat Card Inserter
    1. Width (flat unfolded):
       • Minimum: 7 13/16"
       • Maximum: 14"
    2. Width-folded:
       • Minimum: 4 13/16" low folio, 3 1/2i" high folio.
       • Maximum: 7" high and low folio.
    3. Depth:
       • Minimum: 3 3/4"
       • Maximum: 7"
    4. Insert must be a minimum thickness of .006, with a minimum porosity standard of 20.6 seconds per 100 cc of air passage. (Note: postal specs minimum is .007)
    5. Flat card inserter not available for 2-up, digest-size products.
    6. Perforation on flat card inserts must be a light perforation to ensure that it will not separate during binding. No perforation or score is allowed where card folds. Minimum of 1/4" between fold and perforation.
    7. Flat cards do not count as a pocket, however, use a pocket position for each card.
  • Specifications for Blow-In Card. Inserter (Final Size):
    1. Limit of two blow-in cards in saddle stitched magazine. Both blow-ins must be in the same position. Blow-ins are must be two-page inserts.
    2. Width:
       • Minimum: 3 1/2"
       • Maximum: 5 1/2"
    3. Depth:
       • Minimum: 3 3/4"
       • Maximum: 6 1/4"
    4. Insert must be a minimum thickness of .006, with a minimum porosity standard of 20.6 seconds per 100 cc of air passage. (Note: postal specs minimum is .007.)
    5. The blow-in insert must be promotional piece for the publication(s). Postal regulations limit blow-in inserts to house ads or subscription information. Consult your Postmaster for further information.
    6. The blow-in insert must be placed between binding signatures. Positions available will differ between books with high folio lap and low folio lap.
       • High folio--inserts blow-in to first half of book.
       • Low folio--inserts blow-in to last half of book.
       • No blow-in--center spread
       • No blow-in--inside front or back cover
    7. The blow-in card inserter is not available for tabloids and oblong-size products.
    8. For 2-up digests, limit 1 card in top of book and 1 card in bottom of book.
    9. A blow-in card does not count as a pocket.
    10. The longest side of the blow-in is parallel to the spine.
    11. No blow-in envelopes are allowed.
    12. All perforations must be very light.
    13. Blow-ins are loose, non-calipered inserts.
• INSERTS FOR PERFECT BOUND BOOKS
  • Inserts Through a Regular Perfect Binder Pocket:
  1. Width (untrimmed size)
     • Minimum: 4 1/4"
     • Maximum: 11 1/4" parallel to spine
  2. Depth (untrimmed size)
  • Minimum: 4"
  • Maximum: 15 1/2"
  3. On minimum size inserts, width is governed by depth. Width must be 2" narrower than the depth dimension. Inserts with less than the 2. restriction will have a slowdown charge and may not bind square to the spine.
  4. Inserts on the perfect binders do not require a binding lap; however, they do require 1/8" for mill-off.
  5. Inserts must not exceed the size of the press signatures.
  6. Inserts should be bound between body signatures, not between the front cover and first body signature, or back cover and last body signature. If either of these positions are required, check with your Account Executive for additional costs. Inserts bound in these positions must be the same size as press signatures.
  7. 70 lb. stock minimum on two-page inserts.
  8. 100 lb. stock maximum on 2-page inserts.
  9. 60 lb. stock minimum on four-page inserts.
  10. Unless otherwise instructed, all perfect bound work is jogged to the head.
  11. Tabs on Magnastriped inserts must be strong enough to support weight of insert when freestanding and will require additional binding costs.
  • Flat Card Inserter is Not Available on Perfect Binder.
  • Blow-ins on the Perfect Binders:
  1. Limit of three blow-in cards per copy. (More than two blow-in subject to availability. Please check with your Account Executive three week in advance.)
  2. Each blow-in card uses one binding pocket.
  3. Two blow-ins can not be placed in the same location.
  4. When two blow-ins are used, at least one press signature must be placed between the two individual blow-ins.
  5. Blow-ins cannot be placed inside the front or back covers.
  Note: Following sizes must be based on the base book trim size:
  6. Width:
     • Minimum: 3 1/2"
     • Maximum: 5 1/2"
  7. Depth (longest side of the card):
     • Minimum: 3 3/4"
     • Maximum: 6 1/4"
  8. The depth of the card is parallel to the binding spine.
  9. Insert must be a minimum thickness of .006, with a minimum porosity standard of 20.6 seconds per 100 cc of air passage. (Note; postal specs minimum is .007.)
  10. Blow-in pockets are in permanent locations on all of the binders. Contact your Account Executive for correct location placement.
  • Reverse Lap for Gatefold Inserts:
  1. Between one and three reverse lap inserters available. Consult your CSR for further information.
  2. On a four-page gatefold, the gate is page 1 and 2.
  • Blow on stickers available in line for one binder only.
• CORRECT QUANTITY OF INSERTS TO FURNISH
• Percent of Spoilage for Required Copy Count:
1. 10,000 to 18,000 20.0%
2. 18,001 to 30,000 15.0%
3. 30,001 to 50,000 11.0%
4. 50,001 to 75,000 7.0%
5. 75,001 to 100,000 5.0%
6. 100,001 to 250,000 4.5%
7. 250,001 to 500,000 4.0%
8. 500,001 to 1,000,000 3.5%
9. 1,000.001 and up 3.0%
• Additional Percentage Required for Specific Functions or Requirements:
1. Add 500 inserts for each version change
2. Add 2,000 inserts for each go back per binder setup
3. Tabloid products-add 1/2%
4. If newsprint is used for all, or part, of the bound copy-1/2%
5. Inserts that tip-add 2%
6. Pre-stitched inserts-add 1 1/4%
7. Digest, perfect bound newsprint copies-add 2%
8. Digest, use 2-up count
9. On ink-jet mailing, or any job that requires more than one bindery setup, use the individual binder runs for percent required.
• PACKAGING & SHIPPING REQUIREMENTS
• Cartons and Skid Identification Requirements:
1. Job name
2. Purchase order number
3. Issue or catalog mailing
4. Insert identification code or version
5. Weight and quantity of inserts for each carton and pallet.
6. There can only be one version per pallet when inserts are packed loose on skids,
7. When inserts are packed in cartons on pallets, there can be more than one code; however, they can not be mixed within a carton. All pallets with cartons that contain more than one code must be identified with an 8 1/2" x 11" marker declaring mixed codes and the quantities for each code.
8. All shipments must contain a manifest which itemizes all product contained in the shipment, including quantity and weight by version or code. Vanguard Printing,LLC does not verify weights and quantities received.
9. Inserts furnished for more than one issue must be packed in cartons or separated on skids for each issue.

Note: Sample Label


• Packaging of Inserts or Cartons on Pallets:
  1. Chip board dividers are required between lifts on pallets.
  2. Suggested carton strength is 275 lbs. per square inch of material, single wall.
  3. Cartons to be column stacked-not brick stacked-on pallets.
  4. All pallets with loose material must be plastic pallet wrapped.
  5. Inserts must be packed or placed in cartons in a manner that will not allow the individual pieces to become folded or rolled at the comers or ends. They must be flat in appearance when the pieces are loaded into the bindery pockets, or inserts will be rejected.
• Pallet Requirements:
  1. Width: Minimum 39"; Maximum 40"
  2. Length: Minimum 46"; Maximum 48"
  3. Four-way entry with three 2" x 4" stringers
  4. 1. maximum spacing between boards
  5. Minimum of (3) 1" x 4" bottom boards
  6. Maximum height of 62" or 2,500 lbs. (whichever is achieved first).
  7. Must be capped with a top of either slatted or solid wood.
  8. Tops must be plastic banded to the pallet contents. Minimum of two bands each way to insure containment.
• Delivery:
  1. Insert shipments received earlier than 30 days will be billed $545.00/pallet per month for handling and storage charges.
  2. Delivery hours are 7:30 a.m. to 4:30 p.m. Monday through Friday.
  3. Shipping address:

Vanguard Printing,LLC:

Vanguard Printing, LLC will not be responsible for damage incurred during shipment: quantity received short of the required binding count and spoilage; mixed coded, variance in size, folding trim, etc. If any of the aforementioned is discovered while binding, Vanguard Printing, LLC will finish out the binding without the insert(s) and inform the customer of the finished counts when the job is completed. Any surplus of inserts will be destroyed upon completion of binding unless otherwise notified by customer. Unless otherwise specified in the contract, a charge of $25.00/ skid per month Plus $5.00Each move will be billed for handling and storage charges on inserts received 30 or more days prior to binding date. Vanguard Printing, LLC will not be responsible for any damage to materials while in storage. If you have questions, please check with your CSR.