Production and logistics game B2B: mastering the chain

The TAO is one of the most important - and often the most neglected - steps of a print project and plays three complementary roles:

• Final visual validation - Last chance for the client to spot a typing error, a visual not properly positioned, a Pantone I'm not well-tuned.
• Contractual commitment - Once signed, the BAT engages the customer: if the error appears in the series but it was present on the BAT, the client assumes.
• Production reference - The validated BAT serves as a reference for the printer (more about our specialist game printer) The whole series must look like the BAT.

Digital BAT (PDF)

High resolution PDF sent by email. The client checks on his screen and returns his validation by email. Advantage: fast, free. Disadvantage: no validation of real colors (screen and print differ).

Contracted paper BAT ("Tab Test")

Printing of a physical copy on the final support (cardboard, paper) according to the final process. Sent by mail. Advantage: tactile validation, real visual. Disadvantage: 3-7 days extra time, cost a moderate envelope.

BAT press (machine output)

Validation directly on the press at the start of the draw. The customer (or his representative) validates the first sheets before launching the series. Ultimate level of control, but high cost (customer displacement + machine shutdown).

Customer checklist for the validation of a BAT:

• Text - All spelling errors, missing words, punctuations. Read minimum 2 times.
• Logos and brands - Good logo, good version, good Pantone, respected size.
• Legal notices - EAN number, mandatory information, copyrights, trademarks.
• Colours - Main colours conform to the charter (Pantone verification if available).
• Margins and edges - No elements too close to the edge (risk rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr guillotine cutter).
• Position of elements - Visuals centered, aligned, hierarchically correctly.
• Plating and scoping - For booklets: correct folding, page 1 = cover, etc.
• Format - Correct final dimensions.

• 1. Check source file - Format (PDF, AI, INDD), image resolution (300 DPI minimum), integrated fonts, preserved layers.
• 2. Color Conversion RGB → CMYK (print color standard) - If the file is in RGB (web), conversion to CMJN (printing) with ICC profile adapted to the press.
• 3. Adding lost funds - Extension of the 3-5 mm visual beyond the final format to avoid white fillets guillotine cutter.
• 4. Definition of cutting marks - Print marks for the massicot.
• 5. Distortion - For backgroundless images, proper separation of the subject.
• 6. Pantone setting - If colors Pantone (mark logo), check that the value is well specified and compliant.
• 7. Taxation - Optimal layout of pages/cards on the mother sheet to minimize falls.
• 8. Production of the TAO - Generation of a validation PDF for the client.

Our pre-press service systematically identifies and corrects these common errors:

• File in RGB - Bright colors on the screen that will become dull to CMYK. Conversion + fit.
• Low resolution images - < 300 DPI = pixelization at printing. High resolution file request to client.
• Non-vectored fonts - Risk of substitution if the police are not installed.
• No funds lost - Visual shut down battery in final format. Risk of white netting. Extension requested from customer.
• Overprint Pantone not specified - Random behaviour to printing.
• Black 100% instead of Black 4 colors (CMJN 30/30/30/100) - For deep blacks on large surface.

An ICC (International Color Consortium) profile is a file that describes how a device (screen, printer, press) restores colors. In pre-press, several ICC profiles are used according to the media:

• FOGRA51 - Standard profile offset printing on paper.
• FOGRA52 - For uncoated paper (raw cardboard, kraft).
• SWOP - American profile equivalent FOGRA for offset press.
• HP Indigo digital profiles - Specific to digital presses for precise setting.

The pre-press adapts the files to the ICC profile of the target press to ensure a faithful chromatic return between the design screen and the final printing.

The MOQ exists for two complementary reasons:

• Seeding costs - Some processes (offset, hot foil, cut to shape) require the production of dedicated tools (plates, matrices, shapes) and these seed costs must be amortised on a minimum volume.
• Machine constraints - An offset press cannot produce 50 copies in a cost-effective way: setting and setting takes as long as 50 times as for 5000. The hourly cost of the machine imposes a minimum volume.

The MOQ is therefore not arbitrary: it is an economic threshold that corresponds to the point of equilibrium where production becomes economically viable.

Several levers allow to lower the practical MOQ for a B2B project:

• Choose Digital - For 50-500 copies, digital avoids the MOQ constraints of the offset.
• Mutualizing tools - If the same cutting form is used for several projects, the cost is amortized.
• Standardize formats - Cards in poker format (63×88) or A3 trays (297×420) use our existing tools - no extra booting costs.
• Accept a higher unit rate - For very small run (< 100), a larger margin per unit can be produced in compensation for the small volume.

• Temporary storage - Storage in warehouse after production pending delivery orders.
• Individual conditioning - Individual cardboard for unit shipping (vs pallet for 1 recipient).
• Custom labeling - Name, address, internal reference of the consignee on each package.
• Multi-carrier shipping - Optimal choice depending on destination (Colissimo, Chronopost, pallet carrier).
• Consolidated monitoring - Dashboard to see the progress of each delivery in real time.

• National deployment of HR game - 200 subsidiaries of a company, simultaneous delivery in 1 week. (more about our solutions for companies)
• Educational edition - 800 colleges to receive a game (Bordas Fresque du Climat case).
• Commercial roadshow - 50 outlets with delivery dates staggered according to the transaction schedule.
• Training Stock - Storage at the manufacturer + delivery on request according to the scheduled training sessions.

• Guaranteed time - Contractual commitment on delivery time (J+3, J+5, etc.).
• Real-time tracking - Daily Excel dashboard or export during the operation.
• Dispute management - Clear procedure in case of lost, damaged or refused packages.
• Final reporting - Logistical balance sheet (% deliveries per hour, % refusal, average cost).

Two standard pallets in Europe:

• Europe (EUR-1) - 1200×800 mm. Universal standard, exchangeable, max height charged 1.80 m. Average capacity: 800-1200 kg.
• Industrial - 1200×1000 mm. Wider, capacity 1000-1500 kg. Less exchangeable.

Europe pallets are standard for all carriers and warehousekeepers: preferred for most B2B projects.

Example for standard 30×30×6 cm playboxes:

• Pallet surface: 1200×800 = 96 boxes per layer (actually ~80 with internal setting).
• Height 1.80 m / 6 cm per box = 30 layers.
• Total ~2400 boxes per Europe pallet.

A standard semi-trailer truck contains 33 Europe pallets = ~80,000 boxes. For large-scale industrial projects, it is the reference logistic calculation unit.

• Retractable filming - Plastic film wrapping the entire pallet for stability to transport.
• Labelling - Label loading (weight, content, recipient) + sorting labels if returned.
• Delivery schedule - Car letter or CMR with detailed summary of content.
• Protective hair - Optional: flat cardboard on top for additional protection.

Unlike straight cut at guillotine cutter (which cuts into straight lines with a long blade), the cut to shape uses a metal tool closed which draws the exact contour of the piece to be obtained. This tool - called "shape" or "part cutter" - is composed of flexible steel blades fixed on a wooden board.

The shape is pressed against the cardboard under high pressure (several tons) in a cutting press. The blades penetrate the cardboard and cut it clean according to the contour of the pattern. One single pass allows to cut the whole piece, contour and possible internal holes.

• Oval / round cards - For games that are youthful or playful, coming out of the classic codes.
• Hexagonal cards - Standard strategy games type wargame, modular trays.
• Octagonal cards - Distinctive visual effect, good hand hold.
• Triangular cards - Very specific, thematic use (land games, connection games).
• Square cards with rounded corners - Modern, elegant standard.
• Cut-out tray pieces - Modular tray parts, hexagon cells, etc.
• Custom pouches / envelopes - Game-specific storage.

Three things to anticipate:

• Cost of form - A custom coin cutter costs a moderate envelope depending on complexity, amortized on the series. Net scale savings beyond 1000 cards.
• Time of production - The shape is made in 3 to 5 working days. To be added to the production schedule.
• Material losses - The more complex the shape, the more ineffective the layout on the mother leaf (cardboard drops). Additional material cost of 5 to 15% vs. an optimized rectangular cut.

THE guillotine cutter The principle is simple: a pile of leaves is positioned precisely under a steel blade, which then descends vertically to cut up to 200 sheets in a single stroke according to the model. The first sheet is a sheet of paper, which is then cut vertically and then cut down to a single sheet.

Three elements guarantee accuracy: the blade (drained steel sharpened to 22°), the battery press (which keeps leaves still during cutting), and the rear movable stop (which positions the battery to the nearest millimeter).

Manual massage

Blade operated by a steering wheel or lever. Accuracy dependent on the operator. Capacity 30-80 sheets depending on grammage. Usage: precision finishes, small run, prototypes. Moderate acquisition cost.

Programmable electric massage

CN-controlled motorized blade (digital control). The operator programs the cutting sequence, the machine executes. Accuracy ±0.1 mm. Capacity up to 200 sheets. Standard of the professional printing. This is our main equipment.

Trilateral massage (3 blades)

Three blades that simultaneously cut three sides of a bound book to get a perfectly regular slice. Specific binding use. In corporate board game, used for finishing thick rule booklets.

Almost all board games go through the massicot at several stages:

• Final map cutting - After printing and filming, printed sheets are massaged into 50 card piles to obtain individual cards of final dimensions.
• Cuts game boards - Foldable plates, sheet of leaflets, score sheets: the size massicot with final dimension.
• Rescinding of leaves before filming - To optimize the yield, large printed sheets are sometimes split before coating into smaller sheets.
• Rule Booklet Finishing - Trilateral massicot gives the net songs to the linked booklets.

A standard print template includes 4 elements:

• Security zone - Internal area where important elements (texts, logos) are placed. Usually 3-5 mm from the final edge.
• Visible area - Zone that will be visible after cutting (= final format).
• Lost fund - Extension of the visual beyond the visible area (3-5 mm). Avoids white nets in case of a slight cutting offset.
• Cutting characteristics - Cross-shaped marks indicating to machine where to cut.

The printer usually provides the template in several formats:

• PDF - Universal format, serves as visual reference.
• AI (Adobe Illustrator) - For graphic designers working on Illustrator.
• PSD (Adobe Photoshop) - For photographic visuals worked on Photoshop.
• INDD (Adobe InDesign) - For multi-page booklets.

Always work on the template provided - never create your own "about" file with the right dimensions, under penalty of setting errors.

Once the visual is integrated into the template, export in high definition PDF with:

• Colour profile CMJN (FOGRA51 or equivalent).
• Vectored or integrated fonts in PDF.
• Minimum 300 DPI images on the visible area.
• Lost funds present on all edges.
• Cut strokes activated.

The manufacturer checks the file in pre-press and alerting on any problems detected before production starts.

To launch a corporate board game project without specifications is to ask for a blind estimate. Three almost systematic consequences:

• Imprecise cost - Without clear constraints, the printer estimates the ladle. The final rate may vary by 50-100% from the original estimate.
• Endless iterations - Without a framework, each meeting makes the project evolve in a different direction.
• Final dissatisfaction - The product delivered does not correspond to what the customer had imagined, for lack of formalising his expectations.

A well-made specification avoids these three pitfalls and saves 30-50 % time on the overall project.

1. Background and objectives

Why this project? What business or educational objective? For what event or need?

2. Target audience

Who will play? How many players? Level of prior knowledge? Constraints (language, accessibility)?

3. Desired Game Mechanics

Type of game (plate, cards, roles, cooperative). Duration of a game. Level of complexity. Main mechanics.

4. Technical specifications

Box size, number of cards, type of pawns, accessories (sample, tokens), preferred materials (CSR).

5. Graphic constraints

Graphic chart provided ? Logo to be integrated ? Colors imposed ? Style illustration sought ?

6. Volumes and budget

Expected quantity (range). Target budget (or range). Desired delivery schedule.

7. Compliance and certification

EN71 mandatory ? responsible paper required ? Plant inks ? Specific legal information ?

8. Expected deliveries

Packaging (unit box, pallet, multipack), delivery (what place, mode), files provided (sources, BAT).

• Specifications too vague - "A beautiful functional game". Inactionable. Prefer precise specifications.
• Workbook too fixed - All graphic details imposed without leaving any margin. Limit the creativity of the manufacturer and can generate technical inconsistencies.
• No hierarchy - All the criteria presented at the same level. Prefer "must have" / "nice to have" to guide arbitrations.
• Budget not communicated Without a budget range, the manufacturer cannot optimize the project. Always indicate a range.
• No calendar - Delivery time not specified = risk of misunderstanding. Always fix a target target deadline.

Four steps:

1. Assembly of pages in order, aligned to the back.
2. Strawling of the back - The back is slightly grooved to increase glue adhesion.
3. Application of PUR glue (reactive polyurethane) warm on the back. PUR glue is the most durable on the market.
4. Covering - The pre-folded cover is applied and pressed to fix.

• Professional look - High-end book appearance, printable back (readable title on shelf).
• Sustainability - Modern PUR glue holds decades without detachment.
• High capacity - Up to 600-800 pages technically.
• Large-scale economy - Competitive cost from 200-500 units.

• Minimum MOQ - Economic from 100-200 units. Below, prefer spiral or staple binding.
• Not for fine books - Below 32-48 pages, the glued back is not holding well.
• No flat opening perfect - The booklet closes slightly in contrast to the spiral. For technical manuals requiring free hands, prefer spiral.

Two main families:

• Wire-O - Spiral in double ring metal wire. Professional look, durable, perfect opening at 360°. Premium standard.
• Plastic spiral - Spiral made of continuous extruded plastic. Cost effective, available in several colors, slightly less durable.

Wire-O is widely preferred in B2B for its pro aspect and durability.

• 360° flat opening - The booklet folds on itself, hands free to follow the instructions while playing.
• Robustness of binding - Holds thousands of openings without fatigue.
• Variable capacity - 20 to 200 pages possible with the same technique.
• Customization visible - Wire-O colour can be matched to the customer's charter (black, white, silver, gold, colors).

• No printable back - The spiral prevents writing a title on your back.
• Higher cost in large series - Vs square back glued for volumes >500 units.
• Less high-end look - "technical manual" rather than "book". Dos according to the desired positioning.

A rulebook This structure follows this structure:

1. Coverage - Game title, iconic illustration, mention "Rules of the game".
2. Summary - Indispensable beyond 4 pages.
3. Overview - What will we play in 30 seconds: number of players, duration, final goal.
4. Equipment - An illustrated list of everything in the box.
5. Implementation - What we're preparing before we start, illustrated in a picture.
6. Rolling a tower - The heart of the settlement, step by step.
7. End of game and victory - Conditions and points calculation.
8. Annexes - Variant, special cases, FAQ, lexicon.

Standard technical choices:

• Format - A5 (148×210 mm) the most common. A4 folded or A6 for special cases.
• Interior paper - Bedside 90-115 g/m2 matt satin. Comfortable reading, faithful photos.
• Coverage - Cover 250-300 g/m2 film-coated matt or glossy.
• Binding - Horse staple for 8-32 pages. Square back glued for 32+ pages. Wire-O Spiral for technical use.
• Printing - Standard Quadri offset. Digital for small run.

1. Too much continuous text - Bullet points and illustrations are better than long paragraphs.
2. No illustration of implementation - An annotated photo is worth 1000 words.
3. Police too small - Minimum 10-11 pt for reading comfort.
4. No FAQ - Anticipating common questions in the annex avoids abandonment.
5. No rereading by neophyte - A booklet that's always been tested by someone who never played before.