Producing a Gatefold Brochure

The Brochures

This particular client of mine, the designer, is very easy to work with, in part because she is so complete in her descriptions of her jobs. To begin the bidding process she sent me not only written specs for the job but also a PDF version of an early draft of the brochure showing color and type placement, bleeds, and folding.

The job is 16” x 6” flat, folded to 4” x 6” final size, with the two outer flaps folding in to the center. This is what makes it a gatefold, just as the name implies. After some discussion with the commercial printing vendor, my client and I decided to put the job on a white, uncoated press sheet (Accent Opaque). Specifically, we chose this stock over a fancier paper to ensure that, with the complexity of the folds, the paper would not be likely to crack (as might have been the case with an eggshell or felt finish paper stock).

We decided the paper should be 100# cover stock to ensure that the folded brochure will be thick enough to meet the US Postal Service regulations for automation, to make sure the overall heft of the folded brochure will project a serious and opulent tone for the restaurant client, and yet to make sure the weight of the folded piece will not unduly raise the cost of postage.

My client requested pricing for 1,000; 1,500; and 2,000 brochures.

What makes her mock-up so useful is that it shows the amount and placement of process color on her client’s gatefold brochure. You can see in the PDF sample that the interior of the brochure will have a white background, a row of small color photos across the bottom of the four panels, text, and scattered headlines reversed out of slanted strips of color. The two outside, or rear-facing, panels of the brochure will be light brown, with all brochure cover copy and the back mailing panel printed in black type with black line art. Finally, the fold-in panels of the gatefold are light blue with black surprinted text and line art reversed to white.

With this unfolded visual representation of the brochure as a PDF, I could visualize the final printed and folded brochure, and the offset printer could do the same.

Considerations for the Print Job

I have already mentioned the reasons behind the choice of the paper stock, regarding the physical requirements of the Post Office (size, folding, and placement of the address and other postal information). In your own print design and print buying work, to ensure adherence to postal regulations (i.e., to make sure that the Post Office will mail your job), it is wise to have a business reply mail specialist at your Post Office review a mock-up of your job. He or she can make sure it will be the right size, aspect ratio, and thickness when folded; that the folds will be in the right place to ensure machinability; that the wafer seals or fugitive glue seals will be in the right place; and that there won’t be any surprise surcharges (or worse) due to design or printing problems. It’s always best to get the blessing of the business mail specialist before you print the job.