By: E&P Staff
Aschendorff Druckzentrum GmbH & Co. KG, Münster, Germany, has invested in replacement technology from Ferag, Hinwil, Switzerland, to produce 250,000 copies of 30 daily editions with circulations ranging between 2,000 and 20,000 copies.
On Saturday night, around five million supplements must be split more than 60 times, in amounts of only a few hundred, in a circulation totaling 80,000.
Aschendorff Druckzentrum produces the daily Westfälische Nachrichten, remaining Zeitungsgruppe Münsterland titles and commercial products. Ist mailroom has run three Ferag MSD inserting lines for more than 10 years. The strain on post-press grew over 10 years as copy processing increased by approximately 15% ad the number of titles printed rose by about 20%.
Running three shifts daily except Monday left no time to make up work delayed by mechanical fault.
Given the equipment’s age and utilization rate, and having already overhauled it once to extend its service life, the company has decided to replace the MSD lines between 2012 and 2014.
The building was first expanded to accommodate the greater volumes and splitting. Since January, an offline Ferag inserting line comprising RollSertDrum (RSD) technology has been augmenting the existing systems as an ahead-of-schedule investment in replacement equipment. The plan requires use of four processing lines in such a way that one of the lines can be replaced without impeding operations.
The RSD includes modular RollStream precollecting and six JetFeeder hoppers, soon expnded to eight. Supplements or preprints now can be fed simultaneously — manually off eight JetFeeder units and automatically from two discs. Finished copies are conveyed from the inserting drum to stacking, topsheet application and cross-strapping before resulting bundles are sent to the loading docks.
Supplement changeovers are controlled using LineMaster at a central station, with sufficient time allowed when preparing to change data to a new zoning set-up and care taken when assigning products to the job, according to Ferag. A large monitor above the RollStream line shows the status of preprints and supplements.
With the offline installation, the operation no longer allocates one specialist to DiscPool, one to the MSD and one to the packaging sector. One machine operator at the control station next to the RollStream system can monitor the entire installation, virtually and in reality. Personnel assignment now depends on the number of JetFeeder hoppers required.
Inanother change, when worthwhile, supplements supplied on pallets are during the day using a Ferag roller hopper. Unwinding from a disc during night production causes fewer interruptions, because skewed, buckled and otherwise damaged copies have been removed — which also provides an opportunity to double check products from external sources.
The installaton’s other benfits include flexibility for future expansion and the absence of background noise from the conveyor chain.