It took David Kalvitis over a year and a half to create the Greatest Dot-to-Dot Adventure Book 1. When all the puzzles were tested and the book was finalized, the file from the computer went to Pinnacle Printers, our local Rochester, NY printer. David chooses to use a local printer so he may follow the book throughout the entire process of being made. Why? When a regular text-only book has an error in the printing of the text, generally it does not affect the story. It may not even get noticed by the reader.
However, when making a puzzle book, like our dot-to-dot books, if a number is accidently erased or symbols are switched, it can greatly affect the puzzle while it is being solved. To ensure the quality of his product, David visits the printer during almost every phase of the book making process. The video below shows the progression of the Greatest Dot-to-Dot Adventure Book 1 as it is being put to print. You will see:
. the hundreds of thousands sheets of paper required to make the books.
. the rich colors used for the covers.
. the color quality being checked frequently.
. the inside puzzle sheets being printed. (There are four pages printed on the front and then four on the back of every sheet.)
. stacks of printed sheets ready to go into the folding machine. They are folded in half, and then half again creating a “sig” signature.
. the sigs being placed in the stitching machine. The machine starts with the middle pages and works outward until the cover is finally placed on top.
. staples being added to bind the book and edges being trimmed to make the final 8½ x 11 book.
. the books being shrunk wrapped into packs of 10 to keep them protected and flat. They are then packed in boxes and stored until we ship them out to our customers.