E&D Web--Pursuit of Productivity
Love reveals that PDI's complete CTP processing system has been tremendously efficient for E&D. "Overall, the Prisma plate has doubled the capacity of our prepress department," he says. "Conventional film processing could take 40 minutes under average conditions. With CTP and PDI's automatic processing line, we conserve a half hour per plate of man time and machine time for each of the 250 plates we produce every week. It's a huge savings.
"One of the basic concepts we operate by is to keep things simple," he contends. "Conditions are always changing—papers, PMS colors, use of varnish and temperatures. When issues come up, one of the places we don't have to look is in the plate department. The efficiency we gain in the plateroom is passed on to the pressroom."
E&D Web has made considerable productivity gains there, as well, where it uses its other equipment mainstay, Heidelberg web presses. They have five, from a 1987 Heidelberg M-1000, to its newest, a Sunday 3000 installed in late 1997.
Love says he gained considerable efficiencies using the single-web press. He cites several factors that have made makeready faster and easier. First, independent plating motors make it possible to re-plate all units at the same time and without re-webbing the press. In addition, the blankets are easily changed in seconds. And lastly the pushbutton plating system aids swifter plate change out.
"All told, the Sunday Press reduces makeready by two hours compared with our other web presses," he notes. "Since we average three makereadies every day, we added 25 percent more time to push through more jobs."
Love reports its single-web Sunday Press has also helped reduce paper waste, resulting in 51⁄2 percent savings in total paper costs. And most of all, the new press runs at 2,400 fpm, another 25 percent jump compared to its older presses. Love also adds that PDI plates have helped to reduce paper usage. "Rolling up on press, they were quicker than the competition," he says. "After coming to color, they ran much drier, reducing web breaks. If you're wasting paper, your wasting press time. They go hand-in-hand."