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Panpa Bulletin : March 2006
46 | PaNPa bUlletiN March 2006 ProdUctioN AT IPEX 2006 in England in April, Ferag will be showcasing a number of new products to improve efficiency and out- comes at a variety of levels within the publishing process. The advertising and marketing tool MemoStick is sure to be a popular dis- play. MemoStick labels applied to news- papers and magazines achieve strong market penetration, based on print media with a high level of credibility. Recorded response rates have exceeded all existing advertising methods, mak- ing this one of the most effective direct- marketing tools around. When it comes to postpress process- ing, Ferag will be presenting a world first: a complete processing line on show. It will be based on the UniDrum and will deliver two-up production at speeds of 60,000 stitched and trimmed copies per hour. Innovations include components for the intermediate trim, the ComStack stacker and the SmartStrap strapping machine. They will also demonstrate how the line can be quickly changed over from two-up to one-up produc- tion. Another machine they will be show- ing off is StreamStitch, which can fin- ish stitched quarterfold products with three-side trim on the SNT-U inline. In addition, by integrating RollStream technology, outside stitch-ons and sup- plements can now be added to products inline. XtraWin is designed to get more out of your printing capacity, by allowing commercial printwork produced on web presses to be stitched and trimmed online with no intermediate operation, also in quarterfold. Semi-commercials can be produced on existing newspa- per presses and then stitched, trimmed and enhanced with a high-gloss cover. Publishers and printers can now offer advertisers and readers added value and generate additional income. The Domino service concept allows for the creation of individual solutions for servicing and readiness in post-press, from preventative maintenance work to specialist support. It leads to a longer life-cycle for the overall system. ferag shows off new products When printing house Kreiszeitung Verlagsgesellschaft mbH & Co. (KV) in Syke close to Bremen in Germany built a new printing plant, they knew they faced a challenge of monumental proportions. They needed a system that could cope with a daily print run of a minimum of 320,000 cop- ies of three part editions of three papers: BILD Bremen, BILD West and BILD Münsterland, while meeting the short time window of four hours per night. Their decision was a KBA Commander, con- sisting of two machine sections, with a flexible mailroom solution from Danish post-press specialist Schur Packaging Systems. Horst Stuckenschmidt, Technical Manager of KV, said the investment was needed to pro- vide the BILD newspaper in Nordic Format and the Schur Packaging System best suited their needs. "Capacity, functionality, trustworthiness and profitability were decisive criteria for the mailroom as well as for the machine itself," said Stuckenschmidt. "We know of convincing Schur mailroom solutions within the Dr. Ippen Group. Furthermore, more current references gave us a positive idea of the capacity potential of the supplier. The trustworthy gripper con- veyor TGG 3000 is convincing through a stable positioning of the product during the entire transportation, and runs extremely steadily. "Also, the other Schur components like the four A 600 stackers and the A 855 inserting machine, all comply with the requirements on functionality and capacity. The press and the further processing must be able to work to- gether harmonically at a speed of up to 85,000 c/h, and eliminate all risks. After all, we only have maximum 4 hours each night to fulfil the contracts without problems. "We print in parallel productions daily at 22.00, 22.30 and 0.30 hrs, and must guarantee that the close edition plans for delivery of the BILD newspaper do not start to fall apart. The contractor has given us a small time buffer, but we cannot allow larger delays." back-up solution From both folder exits the gripper conveyor system TGG 3000 takes over the newspaper stream from the pick-up stations into the mailroom. Here, both folders are connected to two high-capacity stackers, type A 600. Based on the capacity, one stacker could handle it, but KV chose the double safety and decided on a so-called back-up solution. The finished bundles are cross strapped and from there led out to the automatic loading bay system, with two loading positions each. The packing lines are prepared for exten- sion by programmed bundle production in- cluding automatic bundle label application, at any time. The line connected to folder 1 is also equipped with a Schur A 855 inserter with three insert feeders, so, if necessary, part of the production can be provided with supple- ments. The machine is in an offline configura- tion, which is independent of the production capacity of the press. In the meantime it has reached a net output of more than 33,000 cop- ies and thus our requirement profile has been fulfilled." Saving time Heinrich Dräger, the department manager for mailroom technique, sees the total project as a big success. "Analogous to the building up time of the press, the installation time and the commissioning phase of the complete Schur system were pleasantly short, so that we had an unexpected head start of six weeks com- pared to our plan. In agreement with our con- tractor, we used this buffer for test production of the part editions. During this time, we could optimise the software of all the components and offer intensive'on the job training to our operating personnel. The press and the mail- room passed the test and produce stably and without interruption." The new system eliminates all risks both by printing and in the mailroom and ensures the contractual fulfilment of the large orders during the cooperation, which initially has an agreed duration of 15 years. Schur provide mailroom solution the essentials > KV have used a Schur tGG 3000 conveyor, four a600 stackers and an a 855 insetting machine to produce 320,000 copies of three papers in four hours > even though they could make do with one stacker, KV decided to go with using two at a time to ensure they would have a back-up if one failed. > the a 855 inserter is in an offine confguration, so it can be used separately or added to the production process to insert supplements. > the system came together so neatly that KV went into production six weeks earlier than planned, enabling on the job training.