No-pack Blankets — Packing Their Troubles Away
In 1996, millions of textbooks were printed in North America. High-quality, high-circulation news magazines, such as Business Week, Time and Newsweek, reported circulations topping 15 million. In the United States alone, 60 million Bibles were produced that year for distribution throughout the world.
With this explosion in commercial web printing and the reduction of profit margins, press operators are exploring new ways to save time and money. For two commercial printers—Quebecor-Hawkins, in Kingsport, TN, and St. Ives, in Hollywood, FL—the solution was a new no-pack printing blanket.
A Blanket Solution
"We realized that a no-pack printing blanket was just what today's commercial web printers needed," notes John Genest, technical service manager at Reeves, manufacturer of the Vulcan Com No Pak blanket.
"Traditional offset blankets that require packing produce excellent results in printability. On the downside, these blankets can also demand significant 'run-in' time, as well as longer makeready time. Blanket technology that would improve printability and hold gauge loss to ±0.001˝ was simply not on the market—not in a no-pack."
Reeves' design engineers developed the Vulcan Com No Pak in 1996, specifically engineered for use without packing sheets on presses that have a 0.071˝ undercut. The fabrics in the blanket's carcass are patented; the blanket's closed-cell construction and compacted fabrics were engineered to reduce on-press gauge loss to ±0.001˝ consistently throughout the life of the blanket.
Quebecor-Hawkins is one of the world's largest producers of Bibles. It is also an industry-acknowledged printer of elementary and college textbooks, as well as other manuals and catalogs.
No Pak, No Sweat
In January 1997, Quebecor-Hawkins installed the Vulcan Com No Pak blanket on its Mitsubishi 55x383⁄4˝ web press. This four-color press has the capability to print a 64-page signature in one pass at speeds reaching 1,800 to 2,000 feet per minute (fpm).
"Our four-unit Mitsubishi press is one of the widest presses on the market. Because of its narrow gap area, it is difficult for press operators to install a blanket, pack it, and keep the packing smooth and unwrinkled," explains Junior Marshall, Quebecor-Hawkins' printing manager.