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Printing (Big) Manuals?

Detritus writes "Many companies have stopped providing hardcopy manuals with their products, electing instead to deliver the manuals in the form of PDF files. This becomes a problem when you have an 800 page reference manual and you need a usable hardcopy that is double-side printed and bound. What is the most cost-effective way of turning a PDF file into a bound document? Cheap ink-jet printers are not designed to do this task at a reasonable speed and cost."

15 of 196 comments (clear)

  1. laserprinters are way cheap now by Tumbleweed · · Score: 2, Informative

    Samsung makes a very nice 1200dpi printer with PostScript, ethernet, and duplex printing, that's available online for around $500. Many people are opting for Samsung laserprinters these days over HP and Brother. We have one at work, and it's really nice, plus the Linux support is appreciated.

    1. Re:laserprinters are way cheap now by drinkypoo · · Score: 4, Informative
      A better option is to buy a refurbished laserjet 2100. I got one with a refilled toner cart and a 90 day warranty for $162.50 shipped. I then spent a further $85 or so getting a 10/100MBPS EIO card (J3113A) for it. The printer will do some kind of fancy print mode at 600 dpi where it varies the size of toner dots, and will print 300 or 1200 dpi as well. It is designed to print 20,000 pages a month.

      For still more money, you can get duplex, a second tray, et cetera. I intend to purchase the postscript simm (about $30) which doubles the memory to only 8MB (sufficient for manuals, though) and provides PS level 2 emulation, to augment the PCL 5 that the printer normally speaks.

      The laserjet 2100 is one of HP's finest black and white laser printers, and you can trivially find one with ethernet, or buy one and an ethernet EIO print server, for less than $300. They are not the fastest printers around but my 2100 will probably still be working when the last 1320 has failed :P

      --
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    2. Re:laserprinters are way cheap now by Pig+Hogger · · Score: 1, Informative
      Even a cheap laser without duplexing can still do two-sided printing. You just have to flip the stack over manually and print even / odd pages.
      ** DANGER ** DANGER ** WILL ROBINSON ** Do NOT re-feed laser-printed pages in a laser printer, especially if you flip them over.

      The xerographic printing process involves a fusing step, where the paper is heated to high temperature between two rollers, in order to melt the powdered ink. Only the roller on the ink side is designed to be impergious to the molten ink, so when you pass the sheet again, the ink will often melt and stain the other roll, which will then stain every following sheet. Fixing it involves replacing the whole fuser unit ($$$OUCH$$$).

      Note: some very specialized printers are designed to allow page-flipping; so make sure that the printer documentation explicitly states so.

    3. Re:laserprinters are way cheap now by Planesdragon · · Score: 3, Informative

      Note: some very specialized printers are designed to allow page-flipping; so make sure that the printer documentation explicitly states so.

      Read "some very specialized printers" as "almost any laser printer sold in the last ten years."

      To be blunt, the way to tell if your manufacturer supports it is to ask them. Some very cheap, commercial-quality printers do this just fine. (The $150 Brother HL-1440 I use not only doesn't have a problem, but includeds a duplex printing mode in its drivers.)

      Oh, and it's not @#$!ing "ink". It's "toner." Ink is a liquid, that, in "inkjets", permeates quite a bit deeper into the paper than tonor-flakes.

    4. Re:laserprinters are way cheap now by arb · · Score: 2, Informative

      ** DANGER ** DANGER ** WILL ROBINSON ** Do NOT re-feed laser-printed pages in a laser printer, especially if you flip them over.

      Rubbish!

      As others have pointed out already, many of today's laser printers are designed to be used with duplex units. There is no problem with printing on the reverse side of an already laser-printed sheet. It's even quite feasible to over-print laser-printed forms.

      What you shouldn't do is over-print onto photocopied forms. That's where you can cause some problems with the toner being "melted" off the paper. Laser printers fuse their toner at a higher temperature than most photocopiers, so the printer will melt the photocopier's toner. Fixing this problem merely entails printing a half dozen or so sheets though, as by then the bulk of the toner will have been refused onto the sheets (which will be "stained" as you point out.) Not an overly expensive fix, but a PITA.

      So some handy hints:

      1) Printing on both sides of your paper is quite safe and environmentally friendly.
      2) Don't over-print onto photocopied sheets or print on the back of photocopied sheets.
      3) Use a good quality toner - some cheap recycled cartridges may cause issues with re-feeding sheets, but generally are fine.
      4) If you do have a problem with the toner from a previous print job causing streaking on following sheets, just print a few test pages until the streaking goes away - shouldn't take more than a few sheets. You don't need to replace the whole fuser unit.

  2. Re:notebook/tablet by Improv · · Score: 2, Informative

    I can understand that ggv has some possibly tricky dependencies, but xpdf is pretty easy to compile on any Unix. I've compiled it on a number of oddball unices without problem.

    --
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  3. PrintFu by rebug · · Score: 5, Informative

    Sounds like PrintFu is what you're after.

    --

    there's more than one way to do me.
  4. Multi-up by redelm · · Score: 3, Informative
    Usually when I have this task, it's for work and I have access to a double sided laser printer. Then I use the printer driver features to print two or four pages per side of 8.5x11" floppy.

    Most large doc are laid-out for printing on smaller paper and are actually oversized on A4/8.5x11. This is only good if you have reduced visual acuity. I don't, and usually go for the 4x to save paper and page flipping.

  5. Cafe Press? by cei · · Score: 4, Informative

    http://www.cafepress.com/cp/info/help/learn_book.a spx does mass printing of PDF files, double-sized, bound. Sure, it costs a little bit, but probably less than trying to pull it off yourself.

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  6. Outscource the job to Kinko's by mysticgoat · · Score: 4, Informative

    I was just looking at a very similar problem:

    • Manual of about 300 pages in .pdf format
    • want double sided
    • want binding that can be used effectively (stay open at desired page)
    • want some durability-- I figure about a year before updates or errata make this obsolete

    The Kinko's in SE Portland quotes me about $25 for a single copy, double side printing, comb bound with vinyl cover. Add $1 to do spiral bound. There would be a discount for multiple copies-- and at this price doing a copy for each of us, and a couple of spares for the Jolt spills, might be a good idea.

    No way I could do this "in house" for such a low cost.

  7. Re:notebook/tablet by Saeed+al-Sahaf · · Score: 2, Informative
    First of all, someone needs to call these companies and scream at them until they stop using PDF. If they never intended to print it, there's no point to PDF for a manual. HTML is just fine, and most browsers (including Mozilla) are more lightweight than the official Acrobat Reader.

    Perhaps they never intend on printing it, but they know many end users will want to, and honestly, HTML is not "just fine" to many people (like me) who appreciate the formatting of the PDF documentation, not the least of which is not having tables and images cut in two (and many other formatting issues)...

    Second, if you need to read any sort of electronic document, why not read it electronically?

    Because for many people, searching and cross referencing data are much more efficiant with hard copy. Many people like having a manual open next to them when they work, and do not like having to flip back and forth to some electronic document.

    --
    "Who are in control, they are not in control of anything - they don't even control themselves!" - Glen Beck
  8. Simple by iamweezman · · Score: 2, Informative

    Staples...or pretty much any office store will always run coupons and specials. Call them, find out what they are, what days they are for, and if they can beat out the competitor. Even if they are the lowest price, they go to insane measures to cut the competitor if they are threatened with it because their profit margin is so high and they figure that they will create return business if they get you the first time.

  9. I work at a printing company. by zeath · · Score: 2, Informative

    I work at a printing company. My work involves printing about 40,000 pages of paper a week. I'm lucky that I can print, copy, and bind anything that looks ITish and make it look like work related. I have spiral-bound copies of a boatload of XServe reference pdfs just because I got annoyed at looking at the pdf on the screen, even though I've only used them the day they were printed and they've been tucked away in a drawer since.

    Now, for something useful to answer the question at hand: Find a local, small printing company. They're all over, you just have to look. Call up and ask to speak to their IT dept. I've done small printjobs like manuals, they're insanely easy and fast to do, and a single copy of a 800 page manual (assuming that means 800 planes, 400 double-sided pieces of paper), 3 hole punched in a binder, would cost us roughly $50 to do. This is not a price quote, just an FYI. Reasonably we'd probably ask about $70 to $100, cheaper if it's for an existing/prospective client or a personal favor.

    If you need lots (hundred or more) of copies, you can go really cheap with the "tissue paper" that prints off of a web press and get them for as little as $5 a copy, depending on how you bind them. Unfortunately, we don't do that where I work but we subcontract work that we get that does need it.

  10. Re:Put more than one virtual page on an actual pag by orasio · · Score: 2, Informative

    Don't be so radical.

    (print even pages)
    psbook -s16 file.ps |psnup -n 2 |psselect -e |lpr -P printer

    (re-feed your pages, print odd pages)

    psbook -s16 file.ps |psnup -n 2 |psselect -o |lpr -P printer

    Will print a nice manual, in several 16 pages booklets, that you can bind with your own stapler in the middle (hint: open the stapler all the way, plus the side of your desk is your friend).

    If you used a nice laser printer (a cheap one will do) then you have a nice, book sized manual, as easy to read as a common book.

    That would be for A4, but if you would like bigger sizes, you can do some tricks to print on legal size, and chop the top and bottom margins, acheiving book-grade font sizes, but you are on your own (hint: man psbook).
    Of course, only use A4.

  11. CafePress / Lulu by bradediger · · Score: 4, Informative

    I needed a manual printed (perfect bound - like a paperback novel) last year and went with CafePress. They have reasonable prices--I think I spent $15 on a 200-page book, one copy. Decent quality, but the pages were a little yellow.

    Then I found Lulu. Same kind of thing, with a base price of $4.53 per book and $0.02 per page. They do have a page limit of 700 pgs, which would translate into a whopping $18.53. Anyone have any experience with them?