Home' Australian Printer Magazine : September 2013 Contents 46 September 2013 - Australian Printer
Printers bag millions
with Ferag polywrapping
Companies worldwide need to
find successful finishing solutions.
Ferag’s high speed polywrapping
technology has given a much
need capability to the UK’s
biggest newspaper companies
EACH week, UK print giant
Newsprinters produces 3.2million
copies of the Sun's week ly TV
magazine at its facility in K nowsley,
Liverpool. The copies are sealed in foil over
a period of four days using only two foil-
w rapping lines from Ferag.
The huge print run forms part of British
media group News International’s activities.
The group needs 19 Colorman XXL’s to print
its own titles: The Sun, The Times,
The Sunday Times and the new Sun on
Sunday. Contract print titles include
The Daily Telegraph, The Sunday
Telegraph, and The Financial Times. The
Sun newspaper enjoys one of the highest
circulations in Europe w ith 2.7million
For years, it has added a TV Guide to
the Saturday edition of The Sun and, until
recently, this product had been printed
under contract. News International
transferred production of the TV magazine
to the Knowsley facility to make better use of
However, before it could start production
of TV Magazine, Newsprinters needed a high
speed foil wrapping capability.
Allan Wain, operations director for
Newsprinters at Knowsley, says, “A total
of some 3.2million copies of TV Magazine
have to be polybagged in only four days.
Our investigation showed that rotary
foilwrapping from Ferag was the most
productive equipment in the marketplace
in terms of the net output speeds it could
achieve. Ferag handles the volume on two
PolyStream lines while other solutions
require at least four lines.”
A tight programme
THE installation schedule from News
International demanded a very tight
programme with only 16 weeks from
order confirmation to f ull live production.
Mark Ellington, group technical director,
expressed delighted with the project.
He says, “ The teamwork between the
Ferag and Newsprinters project teams has
been first class. In more than 30 years of
professional experience, I have not seen
a project of this magnitude completed so
quickly and so professionally.”
The companies had no opportunity to
gradually ramp up production as they had
to ensure the full complement of 3.2 million
copies in the first week.
Ellington says, “With such a short project
programme and no production ramp up,
ever ything had to run like clockwork.”
In its first five months of operation, the
company sealed some 80 million copies of
TV Magazine in foil using the PolyStream
On one of the lines, Newsprinters
installed an in line StreamStitch stitching
system plus EasySert, which has opened
further opportunities for the company.
Wain says, “This w ill enable the company
to develop new products and, for example,
upgrade them w ith a high-gloss cover.”
The two PolyStream lines are fed from
a MultiDisc w inding/unwinding system.
The magazines are trimmed to the correct
dimensions using two SNT-U trimming
drums before transferring to the FlyStream
pre-collecting system where up to nine
supplements along with TV Magazine are
gathered before being sealed in a polybag.
Depending on the quality of the
supplements, the system can achieve a net
output of up to 28,000 copies an hour.
The company says the consistently
high net output results from the sy nergies
between the rotary Poly Pacer sealing system
and other tried and-tested components
from the Ferag product portfolio, such as
the JetFeeder hopper and Flystream pre-
The quality of the foil also plays a key
role. Ferag has helped identify a foil that can
also be printed without incurring a drop in
And using the Intelligent Repair Control
function, any incomplete products are
identified and the missing copy is added
during a second pass.
This guarantees that only complete
products reach the foil-wrapping unit and,
eventually, the recipient.
At the end of the two PolyStream lines,
the sealed copies are securely conveyed
by the TPC Top Performance Clamp to the
MultiStack stackers for processing into
Polybag in Adelaide
FER AG has repeated the success of the lines
in the UK worldwide.
In Australia, print companies can also see
the advantages of the system.
Ian Mar tin, general manager-trade for
Ferag Australia says, “Ferag Australia has
installed three Ferag polybagging lines at the
Adelaide Advertiser where they wrap more
than 100,000 newspapers a night.”
Newsprinters has two Ferag lines at its UK Knowsley plant
Newsprinters needs to polybag 3.2 million T V
magazines in four days
Buyers Guide: Finishing
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