Gannett Offset Sets Performance Benchmark with RTP Trials: Brock Solutions Completes Contract for 9 RTPs
March 2006 - Kitchener, Ontario
For Immediate Release
Brock Solutions, a Kitchener-based engineering company with a core focus on providing innovative solutions to the Printing industry, is pleased to announce completion of a contract awarded by Gannett Offset in Springfield, Virginia, for the upgrade of 9 Static Belt Reel RTPs. The comprehensive Static Belt Reel packages included tension systems for 3 reels on 3 presses, covering all color positions.
Contract Based On RTP Trial Run Performance
The contract was awarded to Brock on the basis of the Brock RTP Unit successfully meeting stringent performance criteria set by Gannett during RTP trials held at their Springfield facility in mid 2005.
The trials involved Gannett evaluating two RTP Units supplied by two different vendors, and utilized the same web leads on separate presses for comparative analysis. The RTP evaluations were designed to determine which of the two RTP units could meet Gannett’s performance targets. Particular attention was placed on significant waste reduction by minimizing registration movement during every paste. Gannett Offset’s registration standards for the evaluation included maintaining registration tolerances within two print dots (<.020”) during the printing of USA Today.
Test Results
Prior to the installation, the waste generated on the customer’s existing RTP varied on average between 150-175 copies for the Under-the-Floor lead. During the trial the Brock system trimmed the waste down on the Under-the-Floor lead to an average of 75 copies per paste. In addition, significant troubleshooting benefits were evident as a result of the standard tools that are part of Brock’s solution. The Paste Log found on the RTP’s touchscreen identified all status information and time stamped all events in the cycle, including web breaks. On this screen up to 256 pastes are stored locally, and issues that could be detrimental to running or splicing success could be diagnosed and annunciated to operators—upstairs or downstairs—with alarms logged in a history so immediate action can be taken to prevent failure or running off the core.
All this information is available for the life of the system in a web-based reporting package, which provides accurate information or reports for every paste and every alarm, as well as reel status information such as Paster percentage and rolls per break.
After the installation of the remaining eight color lead RTPs the average waste reduction is as follows by type of web lead:
- Standard Process Color lead reduced by 20 copies/paste
- Back-to-Back or Comic lead reduced by 50 copies/paste
- Under-the-Floor lead a significant 100 copies/paste
Gannett Comments
Jim Jones, Director of Operations, Gannett Offset, Springfield: “We’ve experienced significant decreases in the waste copies per paste since installing the Brock RTPs. The Diagnostics screens have been an added bonus, giving us detailed paste log information and extensive alarm data right at our fingertips. We were pleasantly surprised by the results, and can honestly say it exceeded our expectations! ”
Brock Solutions' R
TP
The Brock RTP trial unit included a standard RTP package, which consisted of a new RTP cabinet, splice control, AC drive and pre-drive motor, and tension system. Also included was the integration of RTP functions such as RTP status, tension adjustments, belts ON or OFF, etc, into the existing Brock drive system FolderConsole Operator Interface.
On the evaluation reel, the unique challenge was the under-the-floor lead configuration of the evaluation reel.This resulted in a 45 ft. long lead between units, creating a need for more advanced tension control thanstandard process color leads, which typically have 10-15 ft. between units.
The installation of these units was implemented by Masthead International.
About Brock Solutions and Masthead International Inc.
Brock Solutions is an Engineering Solutions company. Brock Solutions' Printing Group specializes in providing technologically advanced solutions designed to minimize interruptions to normal production. Brock's experience and technical know-how applies to the integration of new and existing equipment, while at the same time lays the groundwork for future upgrades.
Masthead International Inc. isa leader in Printing Press Services. Masthead specializes in turnkey press installations, customized rebuild programs, web width changes, engineered reconfigurations, equipment sourcing, and mechanical/electrical audits.
Brock Solutions and Masthead International have joined forces to provide the Newspaper industry with innovative web offset press enhancements designed to increase productivity in pressrooms.
