AICC AICC 40 Years

 

PLANT TOURS

Schedule & Descriptions


Preliminary schedule for Wednesday, April 26
7:30 AM     Depart hotel
8:00 AM     Tour of Community Impact Newspaper
9:00 AM     Load bus and depart for second tour
10:15 AM   Tour of Schwarz/StarCorr Sheets
11:15 AM   Load bus and depart for hotel
1:00 PM     Approximate return to hotel

Schedule times may change.



Description
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StarCorr Sheets

StarCorr Sheets LLC is one of the newest members of the Schwarz Partners Sheet Feeder group.  The greenfield plant was built in 2015 and started production in November 2015.

The plant operates a BHS 110” corrugator.  StarCorr Sheets produces both single and double wall sheets. StarCorr Sheets manufactures B, C, E, and F flute. The Ducker conveyor system has 3 fully automatic lines, complete with:  auto load turning, sheet counters, bottom dunnage inserters, and automatic 4-head banders.



Community Impact Newspaper

Community Impact Printing prints the company’s 23 newspapers for the Austin, Dallas and Houston metros. The company’s Goss Magnum Compact printing presses are unique because there are only four in the world­—in Mexico; Sri Lanka; Staten Island, New York; and Pflugerville.



What You'll See on the Tour
PREPRESS
When the paper is laid out, the designer sends a digital copy to the prepress technician, who prepares the pages to be engraved onto aluminum plates that will transfer the digital files to the newsprint.

THE PLATEMAKER
One plate can hold up to six pages from a newspaper. Four plates are created for each six-page section because newspapers are printed in four layers of colored ink­­—cyan, magenta, yellow and black. Each of the two platemakers can create 24 plates per hour.

THE LASER
A laser engraves digital files onto the plates. The autobender bends the edges of the plates and adds a holepunch so the plates may be loaded onto the press. The press has an autoloader that can load up to 24 plates within 90 seconds. Without this automation, it would take 30-40 minutes to load the plates by hand.

THE ROLL
A technician loads the rolls of paper, which are 50 inches wide and weigh 1,700 pounds. The press can go through up to three rolls of paper in 20 minutes.

THE INKING
Once the press is loaded with the plates, rollers apply the four colors of ink and water onto each plate. Each plate will stamp a reverse image of the newspaper page onto what is called a blanket, which is similar to a rubber stamp. The blankets transfer the original view of the images onto both sides of the newsprint.

THE ALIGNMENT
The press also has an auto-registration feature, which uses cameras to look for colored marks printed on each page to make sure the four colors are being printed in proper alignment. The press notifies the computer that operates it if any marks are out of focus and makes adjustments.

THE FOLDER
The long webs of paper are directed into their proper order before the chopper cuts the paper every 21.5 inches, or the width of two pages, and folds the pages. The two-page sections now resemble a book.

THE STITCHER
The folded sections are dropped on a chain and gathered to create the complete paper. The stitcher then binds the sections together with staples.

THE TRIMMER
Next the bound paper is put into a three-sided trimmer, which trims the excess paper to provide smooth edges. The trimmed waste is then sent back to the paper mill to be recycled into new paper.

THE STICKY
At the insert machine, a small adhesive advertisement is added to the cover while the papers are being loaded.

THE INSERTER
Next the inserter drops in the inserts, or detached ads, into the center of the newspaper. The inserter carries the papers on a conveyor with grippers to print the address on the back covers of the papers.

THE STRAPPER
The papers are then bundled into stacks by ZIP code and postal carrier route. A cover sheet with details for the postal carrier is placed onto the stacks before two plastic bundle straps are added.


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