Inserting system to boost efficiency at news plant

Ferag AG has won its first order in Ireland for an Easysert inserting system, which will be installed by Smurfit Kappa News Press.

Smurfit Kappa News Press has created what is claimed to be the most sophisticated newspaper press line in Ireland following the installation of a MAN Roland Colorman XXL press in 2009.

The Kells factory already operates a range of Ferag equipment, including a UTR pick-up station with TPC grippers, Multistack, Underwrap and Smartstrap facilities, as well as dispatch control and Linemaster control.

One of the attractions of Easysert is its compact size and ability to fit into areas where floor space is limited.

Up to 40 Jetfeeder hoppers can be incorporated into one line, providing the flexibility to meet changing demands.

The maximum speed of inserting is claimed to be 25,000 copies an hour and the finished product can be up to 400-pages tabloid.

The main product format range is from 300mm x 210mm to 310mm x 450mm and the pre-print format from 90mm x 90mm to 310mm x 450mm.

Executive technical director of Smurfit Kappa News, Andrew Attey, said: 'Since the Colorman XXL went into full production we've been looking at other areas where we can add value to the services we provide and inserting was an obvious area to investigate.

An on-line system to the Colorman, which runs at 86,000 copies an hour, would have required a major investment and the Easysert offers an excellent off-line option for a fraction of the cost.

Easysert suits our production capabilities ideally.

We've chosen four Jetfeeder hoppers and a Jobfeed unit to pre-collect products prior to inserting into the main jacket within the Easysert inserter, which will be integrated within our existing Ferag line.

The new Ferag system should go into full production by the middle of February.

He explained: 'We've tired to automate as much of the workflow as possible.

The main jackets coming off the press will be conveyed by Ferag grippers to the Multistack stacker, which can create up to 40 bundles a minute.

These bundles will be strapped by the Smartstrap unit and transported to the inserting system.

The Jetfeeders will handle an array of items, from simple flyers to CDs and these will be amalgamated with the main product prior to wrapping and palletising.

And Attey continued: 'During the first two weeks of December we were given our first inserting work for a regional newspaper, and this had to be carried out by hand.

Ferag's Easysert will allow us to handle inserting extremely cost effectively and enable us to help our customers add value to their products much more easily.

Smurfit Kappa News Press produces a range of titles for News International and Associated Newspapers, including The Sun, Daily Mail, Irish Daily Mail, Sunday Times and Times.

The Kells factory also prints a wide selection of regional titles.

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