FAQ - Convertible Solutions

FAQ

Can I use my folder to seal Fold N’ Go products?

All Convertible Solutions Fold N' Go mailers require 300psi to seal properly.   Relying on your folding equipment to seal Fold N' Go mailers will result in the pieces coming open during mailing.  These mailers MUST be trimmed AFTER folding at a minimum of 300psi to ensure proper sealing.

Do MultiLoft ® Cards need special care?

For maximum archivability, we recommend storing cards @ 77 °F (25 °C) and 20-25% Room Humidity.

Do TRU-Flat® books need special care?

Proper care of TRU-Flat books is very important: recommended storage @ 77 °F (25 °C) and 20-25% Room Humidity.

Can I run MultiLoft ® Inserts through my digital press?

No, MultiLoft ® Inserts are not designed to be run through your digital press.     Once the slip sheets are removed from the product, it can block together while sitting in the feeder tray.

The MultiLoft ® product is jamming between the feeder and the press in my Indigo, what can I do to solve this?

We suggest you make sure the transfer belts are clean.   If the belts on the feeder bridge appear to be loose, they should be replaced.   Fluff the paper before inserting in the drawer glue side down and run the press on heavy substrate mode.

Are there specific handling or use instructions for Convertible Solutions products?

Most instructions have been addressed in the other FAQ’s on this site, but the list included with our products may be more complete.   Click here for a current PDF of the instructions included in every product box.

How Do I Print Variable Data on the Double Thick Cards?

We have found most major imposition software choices on the market today can easily apply variable data to one or both sides of the 2-up cards.   We have also had good experiences with the popular software choices in applying variable data to the 4-up cards when printing a static image on one side and variable data on one side. The challenge has been with printing variable data on both sides of the 4-up card, and we just recently found a great solution. Double Thick Cards have the front and back of the finished card printed on the same side of the sheet.   Designing the imposition layout to handle this unusual arrangement was a problem, but Devalipi Software's Imposition Studio provides a simple and inexpensive solution.   Imposition Studio can easily handle the unusual 4-up double-sided pagination challenge, as well as all of the other simple tasks, allowing your design team to use one software package for every imposition challenge in your shop. Click here for a template that can be used with the Imposition Studio software and the Convertible Solutions 4-up Double Thick Cards.

Are there specific handling or use instructions for Fold ‘N Go products?

Most instructions have been addressed in the other FAQ’s on this site, but the list included with our products may be more complete.   Click here for a current PDF of the instructions included in every product box.

Can I use a cohesive product with a press that uses fuser oil?

The glue performance is impacted by fuser oil flood-coating the entire sheet while printing. Therefore, it is necessary that customers with presses utilizing fuser oil wait at least five (5) hours after printing to allow time for the fuser oils to dissipate before applying pressure to activate the cohesives. We recommend running a confirmation test in this regard to confirm performance before running actual production.  

What is the shelf life of cohesive glues?

Normal shelf life of product utilizing cohesives is   one year from production date, assuming proper packaging and storage. Forms that are left exposed to light and air will see a rapid deterioration in sealing performance. Unused product should be placed back inside their original package until the next use.

What about basis weight of the paper?

The basis weight limitations are related more to the press specifications and folding equipment than they are to the cohesive glue.   In fact, we are applying cohesives to a wide range of papers with excellent results.   Please call us for advise on the proper paper for your application.

Can any paper be used for my applications?

No. Only specific papers are compatible with cohesive glue technology. Use of alternative papers is possible but should be tested.

What effects the sealing quality?

Extended exposure to light and air will cause the cohesives to be less effective.   And as with all substrates, our papers must be properly packaged and acclimated to the print environment before imaging for the best sealing results. Be sure not to print over the glue, or where the glue will adhere, as this will almost completely prevent the sealing to occur.   Lastly, be sure to apply enough pressure with either your cutter clamp bar or clicker press to bond the glues.     We recommend 3 tons of pressure.

Why are my sheets jamming in the folder?

There are a variety of reasons for paper jamming. The heat used in imaging causes a natural curl in the paper, which can cause jamming and folder feeding issues. Feed the sheets curl side down to help this issue. Fan the sheets before folding to allow air to separate the sheets from one another.

Doesn‘t the cohesive have little capsules that break under pressure?

Cohesive glue is not microencapsulated and therefore will not adhere to any substrate other than itself.

How can I tell if I have a good candidate for a Convertible Solutions product?

Almost any product that is mailed in an envelope is a likely candidate for our direct mail templates. Contact us today and let our Product Specialist assist you in customizing a special product to fit your needs.

What is pre-converted substrates?

The paper is delivered with all perforations, scores, die cuts, and glues in-position. After printing, the only required post-press converting is to finish with folding and pressure sealing equipment.

Are there any special handling issues to be considered?

Product should be kept in the original wrap to protect it from air and light. Forms exposed to air and light for extended periods of time before sealing will deteriorate in bonding performance. Unused sheets and rolls should be re-wrapped and stored in their original package.

Can heat or extreme cold affect cohesive glues?

Once manufactured, cold or heat will not affect the product as long as the product is properly stored. The product should be acclimated to a print room environment for approximately four (4) hours before imaging.

If pressure activates the cohesive why doesn‘t pressure from a laser printer cause the activation?

Cohesive glue only reacts when it comes in contact with itself under pressure. Any other pressure and heat has no affect on the cohesive glue.

Why is pressure seal glue called cohesive and not adhesive?

Unlike a standard adhesive, a cohesive requires two patterns placed on top of each other to create the bond. In the case of a pressure seal cohesive, pressure is required to activate the bond. An adhesive glue will stick to any substance and does not require another glue surface to bond.

How is a Convertible Solutions product seal formed?

Folding the form aligns patterns of cohesive glue, which have been pre-applied to the document during manufacturing. Once folded, the document should be placed under pressure to seal the glues.   Activating cohesive products requires a minimum of 3 tons of pressure per square inch to activate the cohesives to adhere properly.

What is pre-converted paper?

Pre-converted paper eliminates post-converting processes such as gluing, perforating, scoring, envelope-converting and other complex finishing requirements. These features are in-position prior to printing, so after the personalized sheet comes off your digital press, the only steps required to finish the piece are trimming, folding and pressure sealing.

What is TRU-Flat®?

  • TRU-Flat® is the trademark for the technology developed by Convertible Solutions used in the production of TRU-Flat products.
  • The simple answer: TRU-Flat ® is the magic that allows the book binding to occur between the pages of papers and the results are amazing.

Is there a maximum number of sheets I can have in book?

  • There isn’t a limit due to the paper, but as a practical matter we recommend hard-cased book sizes of 30 sheets or less.   Books larger than 30 sheets become difficult to press/seal, difficult to handle, and ultimately difficult to enjoy as a finished product.
  • The maximum recommended sheet count for self-wrapped books using a standard TRU-Flat sheet for the cover is 15 sheets.
 

How is TRU-Flat better than the competition?

  • Low cost startup.
  • No cumbersome liner papers to throw away during production.
  • Pages really lay flat.
  • No gutter, no gap, no left to right registration issues.
  • No cross-over color shifting issues.
  • Ability to reposition sheets during the building process.
  • Print & assemble “on-demand” in-house.
  • No need to wait for hours for wet glues to dry before shipping   the finished book. You can ship your book immediately after binding.

How do I lay out the graphics?

  • This is the simplest change to make for graphic artists and the benefits are huge.
  • Every sheet of TRU-Flat paper represents a traditional 2-page spread.   Simply lay graphics out from left to right using the entire print area of the sheet.   There is no gutter so graphics will always be aligned, and since the entire sheet is printed at one time, color match concerns from left to right (across the traditional gutter) are a thing of the past.
  • Self-wrap cover layout is exactly like traditional cover layouts.   Front cover on the right, back cover on the left.
  • You can download a template for graphic layout from our templates page.
 

How can I create a softcover or self-wrap cover for my publication?

Self-wrap is an easy, cost effective, and very popular method to cover books, brochures and proposals.   Simply print your cover graphic on a sheet of TRU-Flat paper.   Fold with the glue side in and wrap the printed sheet around your book block before the final trim.   Press/seal the book with the self-wrap in place and trim to finished size.   The glues on the cover page will adhere with the glues on the outer book block sheets to form a durable and attractive soft cover.

Where can I get hardcovers for my books?

 

  • Some TRU-Flat customers use in-house case making equipment for their other product offerings and they use their existing cases/covers with our products.  TRU-Flat also works with your current cover supplier.

What if my paper representative doesn’t sell TRU-Flat papers?

  • TRU-Flat papers can be purchased anywhere Convertible Solutions substates are sold.   If you’re having trouble finding a representative in your area, please contact us at 866.832.0217 M-F 8:00-4:30 CST and we will be glad offer TRU-Flat directly to you.
 

Will TRU-Flat papers run on my digital press?

  • TRU-Flat papers have been certified to run on HP Indigo and Kodak NexPress digital presses, and we have customers who are successfully running TRU-Flat papers on many other digital printing devices.
  • Contact us today and ask to speak to one of our Product Specialists.   We will be glad to provide you a sample pack of our papers for testing in your specific digital environment.
 

What sizes of books can I make with standard TRU-Flat sheets?

  • TRU-Flat papers support multiple popular book block sizes.
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What kind of paper is this?

  • TRU-Flat papers are currently offered on Options acid free papers.
  • Currently you can purchase TRU-Flat in Options Smooth 100% PC White i-Tone (148gsm).
 

What’s the difference between sheets & pages?

  • One SHEET of TRU-Flat paper spreads from the far left side of the open book to the far right side of the open book.   There is no gutter or binding in the spine area.   We refer to this entire spread as one SHEET since only one sheet of TRU-Flat  paper is used.   Old book binding terms would consider this a two-page spread or two PAGES of the book.   This is probably the most confusing new concept to learn when working with the new TRU-Flat technology, but it makes page layout a snap.
 

How do I assemble a book?

 

Do I need to score the sheet before folding?

  • No scoring is required.
 

Do I need to apply glue to the TRU-Flat sheets?

All necessary glues are already a part of the pre-converted TRU-Flat paper and are activated with pressure.     Nothing needs to be added.

Is heat used to seal the sheets?

  • Heat is not required at any stage of producing TRU-Flat books.   Some cover crimping devices use heat to create the aesthetically pleasing crease at the bind of the book.   These creasers can be used with our products, but heat is not a requirement.
 

What does the Roller Unit do?

  • The Roller Unit uses two motor-driven pressure rollers to apply a consistent seam or crease on the fold of the pages (it does not apply any adhesive as is frequently asked) and it serves as a jig to assist in the accurate application of hardcover cases.
  • We have a few customers who successfully crease the fold of the pages with a simple hand-held wallpaper roller, but this is a slower process and only suitable for low volume production.
  • Many of our videos found at  https://convertiblesolutions.com/panoramic-paper/instructional-videos   illustrate the multi-use Roller Unit.
 

Do I have to buy all of the equipment?

  • If you are already in the book binding business you may already have a suitable device for crimping hardbound covers (cases) to the book block.   This seems to be the most common item.
  • We have also found a number of customers with presses (sometimes called clickers) used in the sealing process of the sheets.   You will want to be sure your press is capable of generating and sustaining an overall pressure of 7-8.5 tons.
  • The roller unit is a custom item and sometimes considered optional in very low volume environments where the TRU-Flat books/brochures will be covered with a self-wrap cover or softcover.
  • Nearly every one of our customers has found the book block jig to be a tremendous benefit with both quality and throughput.   This item is highly recommended.
 

Do I have to buy the equipment from Convertible Solutions?

  • Equipment sets can also be purchased in the U.S. from our representatives.   Contact us at 866.832.0217
  • Equipment sets for our European customers can be purchased from our Convertible Solutions office in Stuttgart, Germany.

Do I need special equipment to make TRU-Flat books?

A few basic pieces of binding equipment are required to build books with TRU-Flat products and they can be purchased in a complete set or as individual pieces.   See our Binding Equipment link from the Products Menu.

Imagine the Paperbilities® and discover new ideas for your next stellar print project. Our customers share creative samples and ideas to get your mind moving away from that blank screen or page and into an outstanding finished product. For your viewing pleasure -- Enjoy!

Paperbilities®

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