Books are printed in "forms," or sheets, of four, eight, twelve, twenty-four, or thirty-two pages at a time, the number being determined to a great extent by the size of the type page and by the class of the work.

An ordinary twelvemo book, without illustrations in the text, is usually printed in forms of thirty-two pages, on what is known as a single-cylinder flat-bed press, which prints only one side of the paper at an impression. For large editions, the size of the sheet of paper is sometimes doubled and sixty-four pages printed at a time. The class of work in question may also be printed on perfecting presses which print both sides of the paper at one time, and in this way as many as one hundred and twenty-eight pages are frequently printed on one sheet, there being sixty-four pages on each side. Large editions of books having small pages, such as small Bibles, are often printed two hundred and fifty-six pages (one hundred and twenty-eight on each side) at one time.

High grade, illustrated books are always printed on one side of the sheet at a time, the reverse side being printed after the first impression has dried properly. Thus a smooch, or "offset," the result of handling the paper before the ink has become dry, is prevented.

For convenience, I shall describe the process of printing a book from electrotype plates on a press which prints thirty-two pages at a time and on only one side of the paper.

Before ordering his paper, the publisher must first determine the size of the paper page of his proposed book, and from this arrive at the necessary size of the sheets of paper. He must also determine the thickness of the paper needed to give the finished book its proper bulk.

If the book is to be trimmed on top, bottom, and front, about one-eighth of an inch must be allowed on top and front for the binder to trim off, and about one-fourth of an inch on the bottom. The dimensions from back to front, including the amount left for the "trim," should be multiplied by eight; and the page dimension the other way, including the trim, by four. This would give the size of paper needed. As an illustration, if the trimmed size of a book is 7-⁷/8×5-³/8 inches, the paper should be 32×44 inches. If the book is printed 16 pages at a time, the paper should be 22×44; and if 64 pages at a time, 44×64.

The quality of the paper and the size of the sheet being decided upon, and the number of pages known, any large paper house can tell the weight necessary to give the required thickness to the book.

On receipt of the printing order, with directions as to whether the book is to be trimmed or not, the printer first makes up what is called a "form" of so-called "patent" blocks on which the stereotype or electrotype plates are placed during the printing of the book. These blocks are made of wood or iron planed to an even thickness of about three-fourths of an inch, so that when an electrotype plate is placed upon one, it will take only a few thicknesses of thin paper between it and the electrotyped page to make the whole "type-high," that is, as high as an ordinary piece of type.

Two adjacent edges of these blocks are bound with strips of brass, which project above the block and are turned over slightly, so as to receive the two bevelled edges of the electrotype plate. The other two edges are provided with movable clamps, which are screwed tight against the flat edges of the electrotype plate by means of ratchets, thus holding the plate firmly in its place.

In practice, the longer of the two brass-bound edges is called the "back" of the block and the shorter one the "head," the other long edge being known as the "front" and the other short edge, the "foot." These terms, as a matter of fact, originated from the use of the same words in describing the printed page of a book, the "back" corresponding with the side of the page next to the binding of the book, the "head" being the top of the book, and so on.

One-half of a set of blocks—thirty-two being a set in this case—are made with the backs on the left and one-half with the backs on the right edge of the block. The common way is to place thirty-two of these blocks, in four rows of eight blocks each, in a "chase," or iron frame, with a cross-bar in the centre. Thus sixteen blocks are on each side of the cross-bar, and all have their backs toward it. The form then appears like this:—

Strips of wood, called "furniture," are then used to fill up the spaces between the blocks, care being taken to see that all the backs, fronts, and heads are in uniform positions. As some people prefer the printed pages of a book to be near the centre of the paper pages, while others like the head and back margins to be much narrower than the margins at the front and foot, the distances between the blocks must be arranged according to the taste of the publisher or the author.

After the blocks have been spaced as desired, and the spaces filled with furniture, the form is "locked up," or tightened securely, with wedge-shaped pieces of iron called "quoins," and it is then placed in position on the bed of the press, securely fastened by screw clamps, and "making ready" for printing is begun.

Notwithstanding the care that has been taken to have all the "patent" blocks and the electrotype plates of even and uniform thickness, there is almost never a case where a form can be put on the press and printed off properly without considerable work being required to make the surface of the plates absolutely flat so that the entire printed part of the page will receive the same amount of ink and will press evenly on the paper.

The first step in making a press "ready" is to place a sheet of heavy cardboard around the cylinder, and over it draw a smooth piece of muslin or cotton cloth. This is called the "packing." In many of the best offices this sheet of heavy cardboard is not used, but in its place is a patent make-ready called "Tympalyn."Over this a thick sheet of manila paper is shrunk, it being pasted under clamps on the front of the cylinder, and carried around and fastened to hooks on a rod on the back. The rod is then turned until the sheet is perfectly tight and smooth.

While the pressman is laying out his plates the feeder should be cutting thin sheets of paper the size of one of the plates. Some of these papers are cut about one inch shorter than the plates for "bevels," and these are pasted on the middle of the full-size pieces. These bevels and the larger "blank" sheets are to go between the plates and the blocks to overcome any variation there may be in the thickness and to make the surface of the form as nearly level as possible. The "bevels" raise the centres very slightly above the edges of the plate, thus reducing the pressure of the cylinder at the points of contact and departure, and saving the plates from wear.

The cylinder being properly packed, and the form of blocks fastened on the press so that the impression of the form will come in the middle of the paper sheets, it is necessary to know whether the binder is to fold the sheets by hand or by machine, and if the latter, what kind of machine, as different ones require different "imposition" or arrangement of pages. This being decided, the plates are fastened on the blocks so arranged that when the sheet is cut and folded the pages of the book will run consecutively. Before levelling up the form with the bevels and blank sheets, the plates of all open or short pages, if any, are replaced with solid pages, as these sheets and underlay are to remain through the printing of all the forms of the book. The rollers are now put in the press and adjusted to just touch the inking table, the ink put on the rollers and distributed, and one impression printed on one of several sheets of thin paper which are run through the press together.[3] This printed sheet is then turned face down by the pressman and any unevenness of the impression noted. One of the printed pages is taken as a standard and by removing as many pieces of the thin sheets as necessary from under the plates where the impression is too heavy, and by adding where it is not heavy enough, the surface of the form is finally "evened," or made as nearly equal as possible.

After this another impression is taken, and of this sheet an "underlay" is made to further "even up" the form. The low places in the individual plates are carefully marked with crayon or a soft pencil on the impression, and the spots so marked are covered with a piece of thin paper. The printed pages are then cut out a little larger than the type page, and placed under the plates from which they were printed. The plates of the solid pages, which had been substituted for the open pages, are now removed, and the open pages are put back in their places on the form.

Up to this point, all the "making ready" which has been done, is of permanent use in printing all of the forms of the book in question. The work that follows has to be done on each form as it is put on the press.

More thin sheets of paper are now run through the press, the number run through together being one less than were printed for the underlay. These printed sheets are used for "overlays," which are very much like an underlay except that much more care is taken in marking any uneven places. A thinner paper is used to bring up the low places in the plates. An impression of the form is then made on the manila paper sheet which had, as before mentioned, been drawn around the cylinder, and on this printed manila sheet this overlay is pasted, the impression on the manila paper being a guide for the placing of the overlay.

Another overlay is now made in the same way as the first; only it will now be found, if the work has been properly done, that there will be only a few spots to be covered with tissue. After this overlay has been made and the necessary pieces pasted over the first one, a thin sheet of manila is smoothly and tightly drawn around the cylinder, covering completely the thick manila sheet with the pasted overlays on it. The form is then ready to print.

While the feeder, as the man who feeds the paper into the press is called, has been "filling in" the overlay, the pressman should have been getting "register,"—that is, moving the plates so that the headlines and the sides of the plates align properly, and that when both sides of the paper have been printed, the pages will exactly back each other. The ink fountain should also have been so regulated by means of thumb-screws that the right amount of ink will run on the rollers and be distributed evenly over the form. Where too much ink shows on the printed sheet, the thumb-screws on the fountain are tightened a little, to decrease the flow, and where not enough ink shows the thumb-screws are loosened to increase its flow. This process is repeated until the "color" is all right. The grippers, which seize and carry the sheets of paper through the press, the reels, cylinder bands, and many other things have also to be adjusted. These cannot well be described, but have to be learned by actual experience.

The "making ready" and watching the sheets as they come from the press to see that the "color" does not vary, is the skilful part of the process. The feeding can be done by a bright boy after a few weeks' experience, but is now done automatically by machines to a great extent.While the press was being made ready, another set of men in charge of the paper have taken it out of the cases or bundles, counted out the number of sheets required for each form, piled it on hand trucks, keeping that required for each form separate, and have delivered it to the press. If a machine feeder is used, the paper is piled on the elevator of the feeder, from which it is automatically taken, one sheet at a time, and delivered on endless tapes to gauges on the feed board of the press, thus bringing every sheet in the same position each time. The number of sheets required for the order are printed from one form on one side and then from another form on the other side.

From the preceding it can be seen that to get a press ready may be a matter of hours, while, in the case of ordinary book work, a press generally prints from 1200 to 2000 impressions and more per hour.

The principal difference between making ready a form on a flat-bed perfecting press with two cylinders and on a single-cylinder press is in extra work necessary to obtain correct registering of the plates and in preventing an offset of the fresh ink on the second cylinder. Otherwise, a perfecting press is very much like two cylinder presses joined together. It has two sets of rollers, two ink fountains, two cylinders, two forms, etc., but only one feed board and one delivery. The sheet is fed to one cylinder and printed, taken from this cylinder by the second and printed on the second side, and delivered on the "fly board" ready to go to the shipping department.

The process of making ready forms containing illustrations is practically the same as for plain ones, except that a new underlay is made for each form, and much more care and skill must be used on the cuts themselves. It frequently happens that one or even two days are spent making ready a form of half-tone cuts, before the actual printing, which takes perhaps half a day to do, can be begun.

In most offices, a special "cut overlay" is made for forms with cuts, or illustrations. The cut is placed on a hand press before the form is made up, and proofs on four different thicknesses of paper are made. The heaviest paper is used as a bottom sheet, and the others are pasted on it. Out of the next to the thickest paper of all, the solid blacks are cut and pasted accurately on the same places on the bottom sheet. From the second or next thinner sheet, the medium shades including the solid blacks are cut and pasted on the bottom sheet, thus building up the blacks and strong shadows. From the thinnest sheet of all, the high lights and very light shades are cut, and the rest of the sheet is pasted on the bottom one. In this way the solid blacks and dark shadows on the cut have three thicknesses on the overlay; the next shades two, and the light shades one, where the high lights are cut out altogether. This is the common form of "cut overlay" used in most offices; but there are many other kinds, some being made on metal by chemical action. All kinds are fastened carefully over the impression of the cut made on the heavy manila sheet covering the cylinder, and the cut must not be moved on the form after the overlay has been fastened on the cylinder, or the effect of all the work will be entirely lost.

One of the great troubles which the printer has to contend with, is electricity in the paper. The pressman is unaware of its presence until he lifts a printed sheet from the pile and receives a slight shock, and finds the sheets stick together. In the case of a cut form, the ink is almost sure to be offset, and in printing the second side of the paper the feeder will have to stop frequently to separate the sheets. Much money has been spent and many devices originated to overcome this trouble. Ink manufacturers make a liquid preparation to be applied to the packing. A row of lighted gas-jets placed near the point where the sheet goes on to the "flyboard," a heated steam-pipe, and many other things have been used, but a new device by which electricity is generated and carried into the press, and there neutralizes the electricity in the paper, is the best of them all.

The printed sheets are counted automatically by the press, and as fast as enough accumulate, they are piled on hand trucks and removed to the shipping room. Here they are "jogged up" so that the edges are even and are counted again by hand. If they are to be shipped away, they are tied up in bundles or nailed in cases and marked for shipment. If the bindery is connected with the pressroom, they are simply jogged, counted, and piled on trucks and delivered in this way.[Back to Contents]