An MK Press & Publishing Systems Ltd World-Exclusive Project

Exclusively appointed by

News International Newspapers Ltd

In partnership with GoIndustry

INVENTORY AND DESCRIPTION
OF EQUIPMENT INSTALLED AT
PLANT ONE, PLANT TWO AND PLANT THREE

• PRESS DATA

• Press Specification
• Reelstand Specification
• Printing Unit Specification

• INVENTORY OF PUBLISHING EQUIPMENT

• H Lines
• VIP Lines

• PUBLISHING EQUIPMENT SPECIFICATION

• Publishing Copy Conveyor
• Strappers
• Inserting System
• Winding/Unwinding System
• Trimming Lines
• Shredders

• PRE-PRESS EQUIPMENT

• CTP Equipment Quantities
• AGV System Quantities
  

Press Specification

Press Manufacturer	MAN Roland
Press Type	Newsman 40	Quantity installed at plant 1: 16
		Quantity installed at plant 2: 8
	Colorman 35	Quantity installed at plant 3: 2
General Description Each press has the make-up of 3 printing units each comprised of 6 couples in a 4 couple satellite unit with two upper couples The presses are divided into odd and even grouping where the even presses can cross select one unit from an odd press to make the even press a four unit press. Each press has five reelstands and can borrow up to three reelstands from the adjacent press making it possible for 8 reels to feed one press Max. colour B/S product from 4 webs = 64pp with 24pp colour Max. colour Tab product = 128pp with 48pp colour Odd numbered presses have one jaw folder. Even numbered presses have one jaw folder and one rotary folder only one of which can be used at one time The jaw folders are designed for a maximum 160pp tabloid The rotary folders are designed for a maximum 256pp tabloid
Cut-off Length	578mm
Designed Web Width	1484mm (Colorman are 1600mm)
Modified Web Width	1474mm
Distance Between Frames	1950mm
Designed Format Sizes	371 x 289mm	Untrimmed Tabloid Format
	578 x 371mm	Untrimmed Broadsheet Format
Designed Printing Area	346 x 275mm	Tabloid Format (to the fold line)
	346 x 550mm	Tabloid Format Panorama
	550 x 346mm	Broadsheet Format
	550 x 717mm	Broadsheet Format Panorama
Modified Format Sizes	368.5 x 289mm	Untrimmed Tabloid Format
	578 x 368.5mm	Untrimmed Broadsheet Format
Printing Speed	12.84m/sec
Newsman 40 Press Speed (Maximum)	40,000cyl.rev./hr
Newsman 35 Press Speed (Maximum)	35,000cyl.rev./hr
Printing Cylinder Circumference	1156mm
Printing Cylinder Diameter	368mm

Click on the image below for a pdf version of the press layout

 

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Reelstand Specification

Number per press	5
Manufacture	EAE
Type	RW EF 2 – 1150
Roll Diameter (Maximum)	1150mm
Roll Diameter (Minimum)	690mm	Min size for splicing
Roll Width (Maximum)	1484mm
Roll Width (Minimum	371mm	¼ Roll
Butt Roll	125mm	+/- 1mm of set value
Method of reel tensioning	Pneumatic
Range of Sidelay adjustment	+/- 20mm	Motorised
Method of Belt adjustment	Motorised
Fast stop performance	6 seconds
Nominal Web	Tension

Printing Unit Specification

Number of units	3
Printing Couples per Unit	6 configured as	4couple satellite units 2 upper couples
Cut-off	578mm
Designed Web Width	1484mm	(Colorman are 1600mm)
Modified Web Width	1474mm
Blanket Width	742-746mm
Cylinder Circumference	1156mm
Dimension between side frames	1950mm
Designed Web Speed	12.84 m / sec
Plate Size	592 x 364.5mm	Single
	592 x 733mm	Panorama
Designed Format Sizes	371 x 289mm	UntrimmedTabloid Format
	578 x 371mm	Untrimmed Broadsheet Format
Designed Printing Area	346 x 275mm	Tabloid Format (to fold line)
	346 x 550mm	Tabloid Format Panorama
	550 x 346mm	Broadsheet Format
	550 x 717mm	Broadsheet Format Panorama
Modified Format Sizes	368.5 x 289mm	Untrimmed tabloid Format
	578 x 368.5mm	Untrimmed Broadsheet Format
Inking system:
Ink Troughs	½ Wide dipping roller, driven by the fountain roller
	Electrically driven fountains Roller (3ph motor/rack mounted ADF5 drive unit)
Inking Roller System	Ink Rail with overshot fountain blade
	Film roller
	3 Ink Distribution Rollers
	2 Ink Vibrator Rollers
	2 Ink Form Rollers
Inking Unit Control	Remote by 24VDC Motors/Blade Position Feedback
	Local Manual adjustment at the inking rail
Dampening System:
Type	MAN Roland Turbo-Dampening Unit
	1 Dampener Vibrator Roller
	1 Dampener Distribution Roller
	1 Dampener Form Roller

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INVENTORY OF PUBLISHING EQUIPMENT

H LINES	QUANTITY	15 LINES EACH COMPRISED OF
INSERTION	1	Combi VAW-TTR Conveyor Station
	1	Combi RA – VDW Infeed Conveyor VD – C7
	1	VDA Combi – H Winding Station
	1	Combi lower belt
	1	Combi VUL – 1C Turnaround Conveyor
	1	VDA Combi – H Rewind Station
	1	Combi VZW Tower Conveyor Station
	3	DTL – H Turntables
	3	DWS – H Robots
	1	ETR – H EP Chain and Grippers
	1	EPUE Conveyor and FAT
	1	Insertion Drum ETR – H (65000 Copies Per Hour)
	3	ETR – H HP / VP Chains and Grippers
	1	HPue Transfer System
	2	VDA ETR – H Unwind Station
	1	VSP ETR – H Buffer Station
	3	Hoppers RA-B
PUBLISHING	1	Infeed Belt and Crusher Unit
	1	Forwarding Station
	1	TTR (Chain, Grippers, ASA's etc)
	1	Delivery Station TTR - AB
	6	IPK Cells
	2	STB Conveyor Lines
	1	Transnorm Conveyor Line
	2	PSB Conveyor Lines
	2	Underwrappers
	2	Strappers (Ferag EASY STRAP)
	2	Turntables
	1	UMK – PKT Conveyor Line
	1	ETB ("E" Type) Conveyor Line
	1	PKT Carousel 22

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VIP LINES	QUANTITY	11 LINES EACH COMPRISED OF
INSERTION	2	Combi VAW – TTR Conveyor Station
	2	Combi RA – VDW Infeed Conveyor VD – C7
	2	VDA Combi – H Winding System
	2	Combi Lower Belt
	2	Combi VUL – 1C Turnaround Conveyor Station
	2	VDA Combi – H Rewind Station
	2	Combi VZW Tower Conveyor Station
	8	DTL – H Turntables
	8	DWS – H Robots
	8	ETR – H EP Chain and Grippers
	2	HPue Transfer Station
	12	VDA Unwind Stations
	6	VSP ETR Buffer Stations
	8	RA Hoopers
PUBLISHING	1	Infeed Belt and Crusher Unit
	1	Forwarding Station "A" (Level 2)
	1	Forwarding Station "B" (Level 4A)
	9	VRP Cells
	3	STB Conveyor Lines
	2	PSS Conveyor Lines
	3	Underwrappers
	5	Strappers Ferag EASYSTRAP
	3	ETB Conveyor Lines
	1	PKT Carousel 22

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PUBLISHING EQUIPMENT SPECIFICATION

Publishing copy conveyor
System Specification Ferag TTR system
Capacity (Maximum)	80000 Grippers per hour
Gripper Pitch	100mm
Pagination range	4 – 300 pages broadsheet
TTR Length at Wrapping:-
Installed Lengths	Line No	Length
	1	186.7
	2	185
	3	197.8
	4	209,9
	5	201.2
	6	205.9
	7	204.1
	8	188.8
	9	168.2
	10	166.7
	11	165.3
Publishing copy conveyor
System Specification Ferag TTR system
Capacity (Maximum)	80000 Grippers per hour
Gripper Pitch	100mm
Pagination range	4 – 300 pages broadsheet
TTR Length at Wapping:-
Installed Lengths	Line No	Length
	12	186.7
	13	185
	14	197.8
	15	209.9
	16	201.2
	17	205.9
	18	204.1
	19	188.8
	20	168.2
	21	166.7
	22	165.3
	23	160.5
	24	164
	25	170.9
	26	168.6
	27	190.8

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Strappers
System Specifications Ferag EASYSTRAP 35 Tandem Cross Strapping System with Underwrapper
Type	ES35.01
Each Comprised of	Two EasyStrap 35 Strapping Machines
Speed (Maximum)	30 Bundles per Minute
Bundle Dimensions	Height Max = 500mm	Height Min = 20mm
Length	Max = 500mm Length	Min = 145mm
Width	Max = 340mm Width	Min = 145mm
Strapping capability	Cross tied
Conveyor Speed	0.3 – 0.8 m/s
Each strapping machine is manufactured to include the following:
	- automatic strap feed - automatic strap eject on end-of-strap / strap failure - manually adjustable bundle stops - tension control system for low, medium & high bundles - control system for low bundle, no strap / low strap tension - conveying system with habasit belts - TEFLON coating on sealer block - environmentally friendly ultrasonic welding system - standard (dual) bundle compression platen - strap coil flanges/operator controls mounted left or right side - emergency stops located on both sides of the machine - pneumatic low tension strap eject mechanism and '"loop" eject - optical machine malfunction indicator - air gun and hose for cleaning

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Inserting System
Type	Ferag V.I.P
Date Installed	1988 (approx)
Speed (Maximum)	2 Drums each of 40000 copies per hour
Maximum end product	300 pages broadsheet
Maximum Capacity	Sunday Times	Main Jacket is dependant on the insert pp
		96pp Pre-Print 1
		96pp Pre-Print 2
		120 (Tabloid) Magazine
	Maximum Total	300pp Broadsheet
Type	Ferag H
Date Installed	1988 (approx)
Speed (Maximum)	70000 copies per hour
Maximum end product	160pp Tabloid

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Winding/Unwinding System
Type	Ferag MiniDisc, VariaDisc and "A" Frames
Speed (Maximum)	80000 copies per hour
Pagination	Up to 128 Pages Broadsheet
Handling of the disks	By Forklift
Intermediate Storage Accessories		Quantity
	MiniDisc Cores	408
	VarioDisc Cores	169
	Disc Pallet "A" Frames	653

 

Trimming Lines
2 x 40000 Drum Trimmers
Shredders
Manufacturer	UNTHA
Year of Manufacture	1992
Model	RS40-4-S
Power	22KW (2 x 11 KW Motors)
Cutting Mechanism	Single 960mm Blade
Suitable Material	Paper

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PRE-PRESS EQUIPMENT

CTP Equipment	Quantities
	Plant 1	Plant 2	Plant 3
Diamond Setter Single	4	3	2
Diamond Setter Double	2	1	1
Glunz and Jensen processor (wide)	6
Glunz and Jensen processor (narrow)		4
NELA Benders	6
WLT Benders		4	3
NELA Sortation Racks	3
WLT Sortation Racks		4	3
Plate Verifier	1	1	1

 

AGV System	Quantities
	Plant 1	Plant 2
Vehicles Lamb	34	15
Warehouse Racks	10	5
Downender	4	2
Hydraulic Power Units	3	2?
Turning Rollers	4	2
Rolaload	2	1
Waste Scale	1	1
Weighbridges	4
Deheader	4
Bilge racks	10
Transfer Carts	80	40
Up-Ender	1	1
CT3000	2	1
CC204	10
Goodall Battery Charges	10
R/S AGV Control Stations	80	40
Alarm Panels	Too heavily modified to be useable by others
AGV Control system	Too heavily modified to be useable by others