Printing Presses & Print Room 198.103


 Goss Metroliner, Ferag,


100,000 copies of full newspapers/ hr.

General Operation & Production Info:

  • Approximately 45,000 copies of full newspapers per hour were produced in the plant. The machinery can produce approximately 45,000 copies per printing press per hour and there are two presses.

  • Press cut off is 22 inches (folder is a 3/2 model and there are two of them)

  • The frame can accept 66 inches (rubber rolls, etc. need to be changed for this) which is triple width on an 11 inch wide paper. The plant ran at 50 inches at start-up and converted to 46 inches along the way.

  • Used 16 reel stands in practice, of which 12 were from an existing site (4/1 units) and four (4) new PPSI 4/4 towers were installed

  • Inks: black tanks stored 16,000 kg and colours 4,000 kg

  • The water system is Ryco/Technotrans, remote control from the press consoles, just like the ink density and register controls are as well

  • Twelve (12) of the sixteen (16) press units (eight per press – each press being equipped with six 4/1 units + two 4/4 towers) came from the an existing site, and all were completely refurbished by PPSI in the UK, or locally for some components (like chroming of the plate cylinders) into 4/1 units (this means 4 colours on one side of the sheet and only black on the other side). The other four (4) units were brand new PPSI (UK press equipment supplier) 4/4 towers (which means full colour process on both sides of the sheet).

  • Each press can output up to 50,000+ copies per hour (for total of approximately 100,000 copies for the two presses), but each Ferag drum in the mailroom can cope with a max production rate of 25,000 to 26,000 copies per hour. In practice, the plant ran the drums at a maximum 24,000 to 25,000, so this means a max of about 50,000 copies per hour for the press when linked with our current mailroom equipment & configuration. Each press delivers to two (2) drums simultaneously and the link between the press and the mailroom equipment is direct, so no buffer time between the two. This means that a production run off the press cannot be accumulated for some hours and then passed in the mailroom later. It all happens in a chain.

  • Each Ferag drum goes to two (2) lines (one at a time is sufficient to cope with the pace), so this way there is a backup unit for everything if production runs into difficulties. The mailroom equipment was run without ever stopping it during production.

  • In other words, there are two press discharge lines (one for press No. 1 and one for press No. 2) which go into four (4) Ferag drums (two per press) which go into eight (8) stacking/bundling lines. Each stacking/bundling line is composed of one (1) Quipp 400 stacker & two (2) Dynaric 1500 tying machines. 

  • The mailroom equipment was all brand new in 2000 except for two of the four drums which came from another of the company’s facilities, but the new ones were the same model and all four drums performed in exactly the same fashion.

  • There are seven (7) hoppers per drum which means that a maximum of seven inserts at a time can be inserted into one newspaper coming off the press. The minimum dimensions are 4 x 6 inches and maximum are 11 x 11 inches for the inserts, as the hoppers can be manually adjusted to these variable dimensions.

  • Each line is equipped with an off-line station, which allows products that are still good but who would have missed one insert, for example, to be passed again just after the main production to complete the count and thus avoiding higher waste.

  • The BDS (Bundle Distribution System) can be programmed with an Allen-Bradley operator interface which enables the exact quantity of bundles to be loaded onto each required truck. The trucks pull up at one of the ten (1) Caljan conveyors as per the dispatcher’s instructions and then the conveyor extend into the trucks to allow the bundles to be distributed to the point of unload. One worker inside the tuck will accept the bundles and pile them until he has the complete count. The system will of course allow for manual override in case bundles get damaged along the way and a need for one or a few additional bundles is required.


P1140033 P1140034
P1140037 P1140039
P1140040 P1140041
P1140042 P1140044
P1140046 P1140047
P1140048 P1140049 
P1140051  P1140054 
P1140055  P1140056 
P1140059  P1140061 
P1140062  P1140063 
P1140071  P1140073 
P1140074  P1140077 
P1140080  P1140081 
P1140086 P1140087
P1140096 P1140097
P1140099 P1140101


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