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A careful study of the materials used in library and in on-demand hard cover binding revealed that, on average, binders keep an inventory of six to 10 different sizes, in 20 to 24 different colors.
Because cutting small quantities from rolls is another expensive and back-breaking task, most binders opt to pay premium prices for pre-cut pieces. These are stored in bins, and must subsequently be cut to the right size. The final dimension is dictated by the actual measurement of the height, width, and thickness of the book block. With some premium covering materials costing $5 a yard or more, waste becomes a significant cost.
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