Guidelines for
Normal Spoilage Allowances

Because spoilage occurs in every bindery operation, your finisher needs sufficient print overruns in order to deliver full counts.

About This Guideline…

The following spoilage guidelines were developed by the Graphic Finishing Industries Association to help customers plan print production needs. Please bear in mind that these guidelines can not apply to every job, so check with your bindery supplier to confirm their spoilage requirements.

Spoilage Allowances > Table of Contents:

• Inserter/Stitcher/Trimmer
• Flat Cutter
• Buckle Folders
• Adhesive Binding
• Mechanical Binding
• Added Finishing Services
  (Die Cutting, Embossing, Foil Leaf, Auto Fold/Auto Glue)
• Additional Guidelines

Inserter/Stitcher/Trimmer

Example:

500,000 finished books of four 8-page signatures. Spoilage allowance 15,500 of each signature, plus 500 (four 8-page signatures; 4 pockets = 3% of 500,000 finished books or 15,000, plus 500 for make-ready = 15,500.)

Signatures received with bent laps could increase this spoilage guideline.

Additional percentages:

• 1 1/2% for one-up oblong books
• 1/2% for all two-up jobs
• 2% for 4-page signatures of 50# book weight or lighter
• 1/2% for each 8-page signature
• 2% for jobs on uncoated stock lighter than 45#
• 1% per vacuum-fed signature

Flat Cutter

1/2% per 1,000 finished pieces

Additional percentage:

1/4% additional allowance for stock with remoistenable gum strip

Example:

500,000 finished 8 1/2 x 11 flat pieces = 1/2% of 500,000 or 2,500 pieces for spoilage. For paper stock lighter than 45# do not use these specifications…consult your finisher.

Buckle Folders

Make-ready/set-up = 1 % of stock for each folder, plus 1 % of the finished pieces.

Additional percentage:

1/2% of the folded finished pieces for each additional folding machine section used whether used in parallel or right angle.

Example:

100,000 17 x 22 sheets folded to 8 1/2" x 5 1/2" (3 right angle folds) to be run on two folders.

Spoilage allowance:

1% of 100,000 or 1,000 pieces (1/2% for each of two additional folding machine sections) plus 1% of stock for each folder set-up.

The following items will increase basic spoilage:

• Curly stock
• Lightweight (less than 45# uncoated)
• Gluing or pasting
• Pin perforation
• Perforations close to the fold
• Gatefolds

When these conditions exist, please consult your finisher.

Adhesive Binding

Up to six, 16-page signatures:

Increase above percentages by 1/4% for each additional form. The following items will affect spoilage for adhesive binding:

• Lightweight (less than 45# uncoated)
• 6- and 8-page covers
• Short forms
• Fold-out forms

When these conditions exist, please consult your finisher.

Added Finishing Services

Mechanical Binding

Mechanical Binding, unlike other binding services requires a very labor intense process. It has different spoilage requirements than most automatic binding methods. In most cases, the material is handled as individual units, unlike automated processes that, after a machine is set, the theoretical "bugs" that cause spoilage, are out of the production process Certainly, some of the spoilage allowances are similar. The following “additional guidelines” also apply to Mechanical Binding.

Please contact the bindery involved, to obtain their spoilage requirements.

Additional Guidelines

The following factors could adversely affect these spoilage guidelines:

1. Condition of material as it is packed on pallets or skids going to the finishing operation.
2. Stock curl.
3. Kind and weight of paper, depending upon application.
4. Numerous lots or codes.
5. Paper that does not lay flat due to heavy ink coverage, special coatings, tape, spot U.V.,
   perfs or scores.
6. Quality control sample pulls should be a consideration.

Keep in mind the following:

• Additional waste occurs in packaging.
• Allowable overrun is an important part of the target figure; therefore, when no underrun is allowed, an additional 10% beyond expected spoilage must be delivered to the finisher
  on most jobs.