Three-Around: A Holistic Solution for Productivity in Newspaper Printing

Think of six broadsheet newspaper pages in the web width and three in the cylinder circumference—all of this at 40,000 cylinder revolutions per hour. That means 1.44 million newspaper pages per web or up to 120,000 copies per hour in straight production. When using the special PFN 35 folder, up to three different editions can be produced simultaneously.

Reader-friendly and economical

manroland web systems (Booth 3143) has embraced the benefits of the triple circumference for industrial applications even for new machine projects and developed an integral, user-orientated concept. Alongside the higher productivity, cost savings can be achieved for paper, consumables, and personnel costs. Both readers and advertising customers love the convenient, layout-friendly format of the compact newspaper.

Three Newspapers Simultaneously per Cylinder Revolution

The core of the concept is the cylinder with three copies in the circumference and six in the width. One lock-up channel receives the printing plate that corresponds to the cylinder circumference, on which three sujets are positioned. An additional cost-attractive option is represented by the 90° position between the printing towers and the folder superstructure. This allows the triple-width unit to be operated like a single-width machine after the printing blanket. The folding system used is the pin folder system PFN 35 with a three-part blade cylinder and a five-part collecting cylinder. The delivery is performed via three copy deliveries with a delivery fan in a continuous shingle-stream. This makes the 50% higher productivity of the concept manageable for the mailroom with existing components. Further production options are provided by the use of an offset former for the deserting of copies as well as for the collection, if a larger number of pages is to be produced.

Pin-Sharp and Highly-Productive

Production in triple circumference is offered by manroland web systems for the COLORMAN and GEOMAN series. In particular the COLORMAN e:line provides new possibilities for the production of advertising inserts due to its high printing quality combined with the flexibility of the triple circumference. Both series have the option of a 11-roller inking unit with three ink vibrator rollers and three ink form rollers, the basis for a uniform print image on full surface ink application. The COLORMAN e:line also shines with a format-sized damper roller for extra low-ghosting printing.

Printing houses all around the world are fighting falling circulations, lower advertising revenue, and higher costs for consumables and personnel. Printers have to be able to systematically implement more economical production concepts of this kind to achieve quick increases in productivity. Particularly in North America, companies often use web width reductions to lower costs. With triple circumference production, manroland web systems is now providing the opportunity to create compact, easy to handle newspapers editions which meet the desires of readers and advertising customers.

Folding System with Triple Delivery

manroland web systems’ engineers have experience dealing with multiple-stream production, through experience with heatset offset 96-page systems. The diverter initially separates one copy from the product flow and then splits the two remaining copies into two streams. This permits high productivity in triple circumference printing even with normal print finishing lines at normal speeds. Furthermore, the delivery via three single streams offers one additional benefit: at similarly high numbers of copies and pages up to three different newspaper editions can be produced simultaneously using the PFN 35 folding unit.