How 3 Ring Binders Are Made

SpeedBinder is a manufacturer of custom imprinted 3 ring binders. We make the binders from scratch in our own plant. Many times, customers have asked what our process is to make 3 ring binders. We thought this was a good opportunity to describe the process

This discussion will center on custom imprinted vinyl binders. Other styles (full color binders, custom imprinted poly binders) are similar.

There are four steps in the binder manufacturing process:

1) Material preparation: Three ring binders are constructed of vinyl and chipboard. SpeedBinder buys vinyl in large, 100 yard rolls. Chipboard is purchased in oversized sheet form. Both of these materials need to be prepared for the next step.

First, the vinyl is "sheeted out" and then trimmed to size. This is the step where rolls of vinyl are converted into sheets of vinyl. Here's a little fun fact: The rolls of vinyl used in the industry are 49" wide. That is not an arbitrary number: It is the exact width needed to get four binders worth of material out of each cut. No matter what size the binder (1", 2", etc), the vertical dimension is the same (a little under 12 inches). With 49 inches to work with, we can get four binders worth, and have a little extra left over for trimming.

Next, the chipboard is cut to the proper size. SpeedBinder uses a large, computer controlled paper cutter for this operation. Each cut is precisely controlled and automatically measured to the thousandths of an inch. The result is an extremely precist chipboard size, which results in a nice, tight fit in the binders. As a last step, the corners on the chipboard are rounded off in a special machine.

2) Heat seal: The next step in the process is heat seal. This is where the materials are stacked together, and then sealed at the edges to produce the shell for the binder.

The heat seal machines operate based on a large turntable. Operators work around the turntable, laying down the various pieces of the binders. As the table rotates, on of the stations has the actual heat seal press. This press is fitted with the appropriate die based on the specific binder being made. The die is warmed, then it is lowered onto the material. At that point, a high-power "radio frequency" circuit is activated, instantly heating the die and liquefying the vinyl. After about ten seconds, the power is turned off and the die raises. At that point, the excess material is pulled away, and a completed binder skin emerges.

3) Silk-screen: After the binders are heat sealed, they are silk screened. This is the process where the customer specific decoration is added.

SpeedBinder uses NorCote ultraviolet cure inks for our silk screen process. This ink is cured using a special conveyor belt dryer. By subjecting the ink to a burst of high intensity UV light, the ink is instantly dried. This allows the three ring binders to be handled immediately.

4) Riveting: After silk-screening, the ring metals are riveted into the binders.

There are numerous options for riveting: Standard rivets or concealed rivets, mount on spine or back cover, round or angle-D, etc. SpeedBinder does them all.

Once the riveting is complete, the binder is complete. They are then packaged and made ready for shipment.

We hope this description has been useful. Please feel free to call us at 888 338 0924 if you have any questions.