Training Manual | Operational Manual

Exceptional Printing for Your Training Manuals, Catalogues, Booklets & More

Copy Direct is your premier source for high-quality printing of training manuals, catalogues, and booklets. We offer superior printing services at competitive prices, transforming your professionally designed files into vibrant, polished products with precision and care. Rely on us for a smooth and efficient printing experience that consistently delivers outstanding results.

Custom Design – Tailor Your Project

Popular Packages – Ready to Go

We cater to a wide range of needs, offering quantities from small runs to large-scale productions.

Your Choice: 4 Easy Steps

Step 1 - Pick a Size
- Choose the size that best suits your project needs.
Step 2 - Pick a Binding
- Select from various binding options to enhance functionality and presentation.
Step 3 - Pick a Cover
- Choose a cover type that reflects your style and branding.
Step 4 - Pick a Paper
- Decide on the paper quality for the interior to achieve the desired look and feel.

Let’s Get Started!

Custom Design – Create Your Own

Key Options for Your Catalogue

Size – Choose your finished size, akin to a closed book size:
- A4: Standard office size (297mm x 210mm)
- A5: Half the size of A4 (210mm x 148mm)
- Custom: Tailored dimensions to meet your specific needs
Binding – Select from various binding options, arranged from lowest price to highest:
- Booklet Binding (Saddle Stitching): Economical for catalogues; pages are folded and twin stapled.
- Plastic Binding: Ideal for technical manuals; allows for easy page addition or removal while lying flat.
- Wire Binding: Popular for catalogues, enabling pages to lie completely flat.
- Perfect Binding: Offers a professional book-like appearance, with the added benefit of printing on the spine.
Cover Options – Choose the card stock for your cover:
- Gloss Finish: Shiny look; available in:
  - Economy: 150 gsm, 170 gsm
  - Standard: 200 gsm, 250 gsm
  - Premium: 300 gsm, 350 gsm
- Matt Finish: Reduces glare and is easier to read; available in similar weights as gloss.
Paper Choice – Select the weight for the contents of your catalogue:
- Economy (80 gsm): Suitable for black and white printing.
- Standard (100 gsm or 130 gsm): Good for both color and black & white.
- Premium (150 gsm): Offers a high-quality, luxurious feel.

4. Paper

Choose your paper weight for the contents of your catalogues, manuals and booklets.

Economy: 80gsm - perfect for black and white printing.
Standard: 100gsm or 130 gsm for colour printing and black & white
Premium: 150gsm for a premium look and feel

Popular Packages – Ready to Go

To simplify your selection process, we offer three popular packages:

Gold Package (Economy)
- Size: A4 (297mm x 210mm)
- Binding: Booklet
- Cover: Matt Finish 150 gsm
- Paper Inside: Uncoated 100 gsm
Platinum Package (Standard)
- Size: A4 (297mm x 210mm)
- Binding: Wire
- Cover: Matt Finish 200 gsm
- Paper Inside: Coated with a Matt finish, 128 gsm
Elite Package (Premium)
- Size: A4 (297mm x 210mm)
- Binding: Perfect
- Cover: Matt Finish 300 gsm
- Paper Inside: Coated with a Matt finish, 128 gsm

Understanding GSM

GSM (grams per square metre) indicates paper weight. The higher the GSM, the heavier and sturdier the paper. For reference:

80–100 gsm: Standard copy paper
128–170 gsm: Heavy paper
200 gsm: Light card
250 gsm: Medium card
300 gsm: Heavy card
350 gsm: Extra heavy card

Commitment to Quality Solutions

We specialize in manuals for education, business, and industry. Training manuals and operational guides are vital resources designed to enhance task performance and ensure consistent content delivery. These manuals are extensively used in various sectors, including:

Retail
Education & Services
Government & Public Sector

Fast Turnaround & Flexible Options

We cater to both large and small format printing, with options for short or long runs. Given the need for frequent updates, our binding methods make it easy to replace old pages with new.

Available Binding Options:

Saddle Stitching
Plastic Spiral Comb Binding
Wire Binding
Wire Binding with a Printed Spine
Fastback Binding
Pur Binding
Ring Binding
Square Fold Saddle Stitched
Tabs

Let us help you create the perfect printed materials for your needs! Contact us today to get started.

Find the binding style that suits you best

The following outlines several different styles of binding for you to consider and choose from.

You will see the following details on each style of finishing to help you choose what is best for the end user application of your manual.

Perfect Binding

Pur binding-106 Perfect binding is the perfect bind. Perfect binding with Pur refers to polyurethane, the type of glue used, which is much stronger and heat resistant than other paper based EVA glues.

Perfect bound books are made up of stacked pages. These are gathered into a book and the edges of the spine are ground off (or notched). When the book block is glued into a paper cover, the pur glue that attaches the sheets to the spine can flow into the notches or ground-off areas. The covers and book blocks are then trimmed flush.

Perfect bound books are square at the spine and use glue to hold the pages, like a paperback book. It gives your books a more professional feel. It can accommodate a page count up to 640 pages (320 leaves 80gsm).

PUR is strong and eco-friendly. Polyurethane Reactive, also called PUR, is a popular glue due to it's superior binding strength and eco friendliness.

Lay-flat - PUR glue is more flexible than EVA glue and provides lay flat qualities when the book is opened. It is ideal for music books and cookbooks, which are read on the desk, and two-page spread such as photo books. This lay-flat quality makes it easy to read books and extends the book life.

Pur binding 2-551 High Binding Strength and Durability - The binding strength is about three times stronger than the EVA glue. Coated paper or specialty stocks, which can be be a problem with EVA, are bound securely in PUR bound books. EVA glue binding strength becomes weaker over time. However, the PUR glue retains durability and flexibility in both high and low temperatures for long lasting book quality.

Another big advantage of the perfect bind is that you can also have information printed on the spine.

What Does A Perfect Bound Book Look Like - click here to view on YouTube.

Saddle Stitch

saddle-stitch-300x188px Saddle stitch booklet catalogue is suitable for 8pp (pages) to 100pp (pages). Finished size is normally A4 or A5 when closed, although custom sizes are also available. This style of catalogue typically has a heavier weight cover (200-300gsm) and content pages (80-150gsm) however some are the same weight throughout.

Saddle stitched is two staples inserted in the spine and folded in half to form a booklet.

This is the most economical method of finishing for a catalogue.

Square Fold Saddle Stitched

sqaure-fold-saddle-stitch300x300px This is a smart new look for full colour books. The square fold produces creased cover sheets, and face trimming to create crisp, sharp square spine booklets that can be opened flat and are easy to handle, stack and store.

Wire Binding

Wire-Binding-300x300px Wire bound catalogue—Wire binding is one of the most popular commercial catalogue binding methods used and is known by a number of different names including twin loop wire, Wire-o, double loop wire, double-o, ring wire and wirebind. With this binding method, the punched pages go onto a "C" shaped spine and then a wire closer is used to squeeze the spine until it is round. Documents that are bound with wire binding will open completely flat on a desk and allow for 360 degree rotation of bound pages.

There are two common hole patterns used in binding documents with double loop wire. Each hole pattern has specific sizes and applications where it is best suited. Here is a quick overview of the different options.

3:1 pitch (3 holes per 25mm) Up to 120 80gsm leaves – 240 pages

The three to one pitch hole pattern is most commonly used for binding small sized documents with double loop wire. Spines for this binding style are available in sizes between 4.8mm and 14mm in diameter. Three to one pitch wires are not available in sizes larger than 14mm. The size of the holes used with this pattern simply does not allow for larger spines to be manufactured.

2:1 pitch (2 holes per 25mm) Up to 240 80gsm leaves – 480 pages

Although a two to one pitch hole pattern is most commonly used for binding larger sized documents it can also be used for binding smaller diameter books. Two to one pitch wire is most commonly used in sizes ranging from 15.9 mm up to 32mm. However, we can use special small sized 2:1 pitch wire for binding documents as small as 6.4mm.

What Does A Wire Bound Book Look Like - click here to view on YouTube.

Plastikoil

Plastikoil-Binding300x300px Also known as spiral binding, plastikoil is a commonly used book binding style for creating documents, reports, presentations and proposals. Documents bound with coil can open flat on a desk or table and offer 360 degree rotation for easy note taking. The continual spiral binding gives document security and ease of use to the end user. Standard color is black but other colors are available.

Wire Binding with a Printed Spine

Wire-Binding-with-printed-spine300x300px This method of wire binding allows for a spine making the catalogue easy to identify when lying in a stack or in a book shelf. Wire is a traditional 3:1 and 2:1 pitch wire binding option. Available in a wide variety of colours, wire binding gives all your bound documents a classic look.

It can accommodate a page count for 3:1 wire of 240 pages (120 leaves), 2:1 wire of 480 pages (240 leaves)

Plastic Comb Binding

Plastic-comb-binding300x300px This binding method is good for technical manuals that have a lot of pages and must lie flat. The stack of pages comprising the book is punched with a series of holes along the binding edge through which a plastic comb is inserted.

Plastic comb binding can accommodate a page count for circle ring of 500 pages (250 leaves), oval ring of 900 pages (450 leaves). Pages can be added or removed as needed. Available in a wide range of colours.

Ring Binder

Ring binder catalogues are very useful for operational manuals or any type of manual or catalogue that is going to be updated. Pages can be easily removed and replaced. Inside pockets, 2, 3, or 4 ring binders are available.

Another popular option to consider when using ring binders is tabs that are used to separate topic sections. Tabs make it easy to find the right information in a ring binder quickly.