CONSISTENCY IN MAINTENANCE AND WASTAGE
CONTROL IN NEWSPAPER PRINTING INDUSTRY
A PROJECT REPORT
Submitted by
PARAMESHWARI R
SANKARESHWARI M
YASHINISRI E
MAREESWARAN M
in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
in
PRINTING TECHNOLOGY
COLLEGE OF ENGINEERING GUINDY
ANNA UNIVERSITY::CHENNAI 600 025
APRIL 2015
ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report “Consistency in Maintenance and Wastage
Control in Newspaper Printing Industry” is the bonafide work of
PARAMESHWARI R
2011113018
SANKARESHWARI M
2011113028
YASHINISRI E
2011113036
MAREESWARAN M
2011113040
who carried out the project under my supervision.
SIGNATURE
SIGNATURE
Dr. N RAJESWARI
Mr. K. VIPINENDRAN
HEAD OF THE DEPARTMENT
ASSOCIATE PROFESSOR
Department of Printing Technology
Department of PrintingTechnology
College of Engineering, Guindy
College of Engineering, Guindy
Anna University, Chennai.
Anna University, Chennai.
ACKNOWLEDGEMENT
We convey our heartfelt gratitude to Mr. K. VIPINENDRAN, Associate
Professor, Department of Printing Technology, for the development of Project
and for their continued support.
At the outset, we sincerely thank Dr. N. RAJESWARI, Head of
Department, Department of Printing Technology, for her support and guidance.
We also thank the faculty members, Department of Printing Technology,
for their valuable inputs, which greatly helped us in carrying out this project.
We are greatly intended to the General Manager – Technical
Mr. V.S. NARAYANAN of DINAMALAR, Chennai and his team for
allowing us to carry out the project in their premises. We also thank our family
and friends for their support and criticism, which helped us to strive harder.
i
ANNA UNIVERSITY
CHENNAI 600 025
ABSTRACT OF THE PROJECT
Degree
:
Bachelor of Engineering
Branch
:
Printing Technology
Title of the Project
:
Consistency in Maintenance and
Wastage Control in Newspaper
Printing Industry.
Name of the students and Roll no
:
Parameshwari R
2011113018
Sankareshwari M
2011113028
Yashinisri E
2011113036
Mareeswaran M
2011113040
Name and Designation of Guide
:
Mr. K. Vipinendran
Associate Professor
Department of Printing Technology
College of Engineering, Guindy
Anna University,Chennai – 600025
Signature of Candidates
Parameshwari R
Sankareshwari M
Yashinisri E
Mareeswaran M
ii
ABSTRACT
In Newspaper industry, maintenance and wastage control are the major
parameters. This project attempts to analyze the various parameters which
Causes paper wastage and to minimize paper wastage in newspaper printing
through finding causes and applying necessary corrective actions.
Maintenance is used to extend the useful life of an asset. Proper and
planned maintenance will improve the production capacity with the existing
capacity utilization itself.
We have analyzed both the Maintenance and the major problems of the
wastage control and found the remedies for those problems to reduce the
wastage in the Newspaper organization.
iii
TABLE OF CONTENTS
CHAPTER NO
1.
PAGE NO
ABSTRACT OF THE PROJECT
ii
ABSTRACT
iii
LIST OF FIGURES
vii
LIST OF TABLES
viii
LIST OF CHARTS
ix
LIST OF GRAPHS
x
INTRODUCTION
1.1.
1.2.
1.3.
1.4.
1.5.
2.
TITLE
OVERVIEW OF DINAMALAR PRINTING PRESS
1
1.1.1. Company profile
1
PREPRESS SECTION
1
1.2.1. Violet CTP plates
1
1.2.2. Reasons for using violet plates
2
PRESS SECTION
2
1.3.1. Press specification and setting
2
ELECTRICAL DEPARTMENT
4
1.4.1 Electrical drives used
5
SCOPE AND OBJECTIVES OF THE PROJECT
5
DINAMALAR STANDARD OPERATING PROCEDURE
2.1.
CTP ROOM STANDARD OPERATING PROCEDURE 6
2.2.
PRINTING UNIT
8
2.2.1. Reel Un-loading procedure
8
2.2.2. Reel loading procedure in reel stand
8
2.2.3. Auto pasting cycling procedures
9
2.2.4. Paper path procedure
9
2.2.5. Machine starting procedure
9
2.2.6. Machine stopping procedure
10
2.2.7. Plate fixing procedure
11
iv
3.
2.2.8. Blanket fixing procedure
11
2.2.9. Blanket removing procedure
13
2.3.
INKING UNIT
13
2.4.
DAMPENING UNIT
16
2.5.
WORKING SYSTEM AND TECHNICAL PROCEDURE
21
2.5.2. Folding Unit
23
DINAMALAR MAINTENANCE PROCEDURE
3.1.
4.
2.5.1. Reel Stand
MAINTENANCE
29
3.1.1. Objectives of maintenance
29
3.1.2. Preventive maintenance
29
3.1.3. Prediction maintenance
30
3.1.4. Breakdown maintenance
30
3.2.
MAINTENANCE SYSTEM FOR CTP
31
3.3.
MAINTENANCE SYSTEM FOR MACHINE
33
3.4.
MAINTENANCE SYSTEM FOR COMPRESSOR
44
3.5.
MAINTENANCE SYSTEM FOR GENERATOR
47
3.6.
RO PLANT MAINTENANCE
49
3.7.
FOUNTAIN SOLUTION
51
WASTAGE REDUCTION ANALYSIS
4.1.
INTRODUCTION TO NEWSPAPER PRINTING
55
4.2.
PAPER MANUFACTURER DETAILS
55
4.2.1. Need for importing paper
55
PAPER WASTE REDUCTION
56
4.3.1. Newsprint waste and its classification
56
4.3.2. Significance of waste reduction
58
4.3.3. Reasons for different waste
58
4.3.4. Comparison of 3R’s of waste management
59
4.3.
4.4.
REASONWISE WASTAGE COPIES (NEWSLINE 45) 62
v
4.5.
REASONWISE WASTAGE COPIES (CITYLINE )
63
4.6.
WASTAGE CONTROL ANALYSIS
64
4.6.1. Wastages and production efficiency in project date 64
5.
4.6.2. Reasons for initial wastage
66
4.6.3. Start-up waste analysis for January-2015
66
4.6.4. Start-up waste analysis for February-2015
70
FINDING AND FACTORS
5.1.
PROBLEMS FOUND IN DINAMALAR PRESS
75
5.2.
MAJOR PROBLEMS
76
5.2.1. Web Break
77
5.2.2. Auto pasting failure, auto pasting copies
78
5.2.3. Folder Jam
81
5.2.4. Air tube burst
82
5.2.5. Registration out
82
5.2.6. Plate scumming
83
6.
SUGGESTIONS AND CONCLUSION
7.
REFERENCES
vi
84
LIST OF FIGURES
S.NO
CONTENTS
PAGE NO
3.1
Computer to Plate System
31
3.2
Diesel Generator
47
3.3
RO Plant
49
3.4
Dosatron (Fountain Solution Doser)
52
vii
LIST OF TABLES
TABLE.NO
1
CONTENT
PAGE NO
Wastage and production
Efficiency in Dinamalar press
64
2
Initial waste analysis for January
67
3
Initial waste analysis for February
71
viii
LIST OF CHARTS
S.NO
CONTENTS
PAGE NO
4.1
Contribution of Different Waste
58
4.2
Cause and Effect Diagram for News Line 45 – Jan 15
62
4.3
Cause and Effect Diagram for News Line 45 – Feb 15
62
4.4
Cause and Effect Diagram for City Line Express – Jan 15
63
4.5
Cause and Effect Diagram for City Line Express – Feb 15
63
4.6
Paper Waste due to web break City Line Express
65
4.7
Paper Waste due to web break News Line 45
65
ix
LIST OF GRAPHS
S.NO
CONTENTS
PAGE NO
1
Initial Waste Analysis for City Line Express – Jan 15
68
2
Initial Waste Analysis for News Line 45 – Jan 15
68
3
Initial Waste Analysis for City Line Express – Feb 15
72
4
Initial Waste Analysis for News Line 45 – Feb 15
72
x
Why Dinamalar?
Dinamalar is the brand ambassador for Manugraph industries limited. It is
the only company in India who uses 100 percent made in India printing
machines.
The printing quality results and output is at par with any international
printing machine suppliers.
They don’t call any more quality control in Dinamalar its called quality
assurance.
COMPANY PROFILE
Name of the company
:
Dinamalar
Founded by
:
T.V. Ramasubbaiyer
Address
:
#38,39, first floor,
Whites road,
Royapettah,
Chennai – 600014
Contact number
:
044-2854005
Fax number
:
28540010
Web site
:
www.dinamalar.com
Branches
:
Chennai, Coimbatore, Madurai,
Pondicherry, Tirunelveli, Nagercoil,
Trichy, Erode, Vellore, and Salem.
Make of the machine:
 City Line Express
 News line 45
CHAPTER 1
INTRODUCTION
1.1. OVERVIEW OF DINAMALAR PRINTING PRESS
1.1.1. COMPANY PROFILE:
Dinamalar is a leading Tamil daily newspaper publications company
founded by Thiru. T.V. Ramasubbaiyer, We underwent our project on
Consistency in Maintenance and Wastage control in Newspaper printing
industry of Manugraph Newsline 45 and Cityline 35 machines used for
production at Dinamalar press located in Medavakkam, Chennai. Circulation of
Chennai plant per day is about 1.8 lakh copies which covers three districts
namely Chennai, Kancheepuram, Tiruvallur and also to New Delhi, Mumbai
and Port Blair.
1.2. PREPRESS SECTION:
The prepress section is equipped with COBALT-4 Plate-setter and Plate
processor. The semi-drum type manual feeding image-setter has a resolution of
1500 dpi. Polkadots manage it 3.5 is a software used to manage the received
data which then converts the PDF documents into EPS and EPS is finally
converted into a TIFF file as the image setter accepts only TIFF inputs.
The pagination software used is Quark express 5.0, Art pro and News
pro. Once the Encapsulated postscript file is pasted in PS Quark Express the
page numbers are automatically generated. The plates used are CTP plates made
by Fuji and Technova.
1.2.1. Violet CTP Plates:
Approximately two thirds of newspaper CTP installations are equipped
with violet plate-setters, the main reason for using violet plate is because of its
1
benefits such as unbeatable speed, unbeatable laser reliability, low cost of
ownership, excellent image quality and so on. The newspaper printing industry
will continue to use violet CTP for these very reasons and that is why thermal
CTP has not been as popular as violet in newspapers.
1.2.2. Reasons for using violet plates
The reliability (lifetime) of the violet diode is significantly higher
than the reliability of thermal diodes which is why some suppliers are offering
violet laser warranty over the lifetime of the plate-setter. For newspapers, the
reliability requirements are paramount, with everything dependent on the need
to produce the plates quickly in the short time available before the press starts.
1.3. PRESS SECTION:
The machine used for main production is Manugraph Newsline-45
and City Line express. The inline coldest press consists of six Y type printing
units each enabled with three printing couples and three H type blanket to
blanket type printing units each enabled with two printing couples. This
machine is capable of printing 45,000 copies in an hour and it has certain
special features such as two arm auto splicers, automatic ink filling, remote ink
key adjustments, automatic lateral and circumferential registration control and
automatic cut-off control which reduce the manual errors during press run.
1.3.1. Press Specification and Setting:
Dampening pH
: 4.5-5.5
Dampening conductivity
: 1300-1600 micro mhos
Cylinder to former ratio
: 1:2:2
Printing cylinder to main shaft ratio
: 1:3
Folder speed
: 45,000 cph
2
Circumferential movement of
printing cylinders
: ±3 mm
Lateral movement
: ±3 mm
Blanket thickness
: 1.95 mm ± 0.02 mm
Cut off length
: 546 mm
Blanket packing thickness
: 0.23
Undercut
Blanket cylinder
: 2.08
Plate cylinder
: 0.24
Hardness of the water form rollers
: 22˚ - 25° shore
Hardness of the ink form roller
: 25° - 28° shore
Maximum ink form roller tolerance
: upto 30° shore
Maximum dampening roller tolerance : upto 40° shore
Rubber inking rollers should be deglazed to maintain the nap (do not to cover
the nap on the surface of the ink form rollers) hardness and ink transfer
properties.
The circumference of the cutting and folding cylinder’s diameter is two times
that of the printing cylinders circumference.
As for as head and tail margins are concerned they are maintained constantly
perhaps it is automatically done by the Autotron. Margin at the fore-edge varies
and is not considered as a major problem, since the same machine is used for
book works and supplementary are printed in the same machine the side
alignment is altered every day.
3
Side margin
: 10 mm
Top and bottom
: 13 mm
Centre
: 20 mm
Paper caliper
: 42, 45, 48 GSM foreign and local Papers
1.4. ELECTRICAL DEPARTMENT
150 KW, 1500 rpm dc motor is used as a prime mover. From the
motor pulley power is transmitted to main shaft through belt drive. In shaftless
presses ac motors are used for individual units. During maintenance terminal
wires has to be aired to clean in order to identify the numbers in wires.
DC drive description of Newsline-45:
Speed (rpm)
: 1500
Type
: DC shunt motor
Drive
: Baumuller 500 amphere
Armature
: A-224
Armature voltage
: 440 V
Field A
: 7A
Field V
: 220 V
Power
: 90 KW
Stabilizer
: 500 KW servo stabilizers with automatic
Power factor control system
4
1.4.1. Electrical Drives Used
Number of motors in a Y-type unit for various purposes:
 3-lateral registration
 3-circumferential registration
 3-inking
 3-dampening
 1-oiling
 1-compensator
 3-brush rollers
 1-reel arm
 DC motors are used in: Main drive, ink and dampening1500 rpm
 AC motors used in: Reel arm, brush, oil and compensator,
register control-300 rpm
Scalar system is the method of controlling the entire machine remotely
through GOT-Graphical Operations Terminal. Brush and dampening form
rollers are replaced with the latest spray dampening system.
SCOPE AND OBJECTIVE OF THE PROJECT
To study the various parameters which causes paper wastage and to
minimize the paper wastage in newspaper printing through finding causes and
applying corrective actions.
5
CHAPTER 2
DINAMALAR STANDARD OPERATING PROCEDURE
2.1. CTP ROOM STANDARD OPERATING PROCEDURE
CTP processor water circulation unit
Tank
 Water capacity of the tank is 40 liters.
 Water to be changed at every 40 plates used.
 Only RO water should be used.
 Always check the water level in tank.
PH level in water circulator
 PH level should be checked once water is changed.
 PH should be checked after every 10 plates.
 Water PH should be checked at the end of the job.
Filter
 Filter microns should be between 50 & 100.
 Water filter should be changed after every 3600 plates used.
CTP Room Policy
Room temperature
 Store room 21°C.
 CTP and processor room 22°C.
Air conditioner operation
 Every Alternative days use alternate A/c.
6
 In CTP and processor room use A/c alternatively.
 For Store room also, A/c runs 24 hours alternatively.
Machine base
 Wooden floor with vinyl sheet.
Plate consumption and usage
 Full plate: for colour pages.
 Half plate: for B/W pages and half web colour pages.
Plate and chemical storage
 Plates must be properly kept in plate storage rack.
 Chemical must be properly kept in chemical rack.
Material ordering procedure
 Purchase requisition entered in software and approved by GM technical.
 After approval by GM, PO raised by purchase department and items
purchased.
Plate consumption and waste entry
 Plate consumption and waste entered in software and mail sent to higher
officials every morning after production automatically.
Replenishment usage procedure
 110ml per sqm taken by processor at production time.
 45ml per hour taken when standby mode.
 30ml per hour taken when close down mode.
7
Developer usage procedure
 2000sqm or 30 days period.
GUM usage
 Gum usage 1:1 with water.
 Gum storage is 4 liters in tank.
 Gum replenishment is 30ml per sqm.
2.2. PRINTING UNIT
2.2.1. Reel Un-loading procedure
 Reel un-loading from truck through fork lift with reel clamp device
attachment.
 Weighed ensure for the reel damages, mark and report.
 Store - Make or Brand wise.
 Enter reel details through proven software system.
2.2.2. Reel Loading procedure in reel stand
 Ensure reel size and auto pasting arm position either to 100cm or 127cm
 Load reel with side margin scale and ensure lateral adjustment almost to
center Position.
 Ensure reel shaft air filling with required air pressure.
 Brake Air pressure / Tension control value is to be set as per the
requirement.
 Ensure-Reel shaft condition before loading.
 Prepare another reel with auto pasting preparations before the end of the
previous reel.
 Reel arm brake position is to be checked before reel loading.
8
2.2.3. Auto pasting cycling procedures
 When the minimum diameter (140 mm for Manugraph presses) reaches
the particular sensor will command for auto pasting then the new reel will
lifted up to the prescribed height, should be 10mm gap between reel and
sponge roller or the brush. This height will be controlled by another
sensor mounted in Autopaster.
 When the reel reaches the height the electro-mechanical clutch will
operate the belt arm to touch the reel and rotates with the help of belt for
initial rotation, when the machine speed matches with reel speed the
pasting is done with old reel with help of double side tape or pasting glue.
After pasting is done the knife will cut the old reel.
2.2.4. Paper path procedure
 Web lying done manually over the cleaned path rollers.
 All web guide runner paths direction should be marked with respective
printing unit as per print pagination.

As per the printing schedule Ensure printing unit with respective web
path, selection done either for regular print path or Balloon 1 or
Balloon 2 or Bay window.
2.2.5. Machine starting procedure
 Reel preparations done as per pagination requirements (All reels, cut
waste, wrapper waste must be weighed).
 If need , Half reel stoppers are to be fitted or removed.
 Reel brake value is to be checked, if need to be adjusted to yesterday’s
value.
 Reel arm brake positions are to be checked before reel loading.
 Ensure unit to unit coupling marks in impression condition.
9
 Ensure for web sensor position and cleaning.
 Check ink level in all ink duct and then insure for ink sensors in “Auto
mode” ON condition.
 Ensure Blankets for cleanliness and for its condition.
 Ensure for Plate cylinder cleanliness.
 Ensure for Web path in respective units in proper web path runners.
 Check water level in all water trays.
 Ensure for ink washing device “off” condition in all section.
 Ensure for ink charging in all sections before start of printing.
 Ensure ink key opening in all colors, as per image requirement by using
CIP 3 auto Initiators.
 While printing make sure for the following check for after every
100 copies.
o Page side margin.
o Page ink density control and gray balance.
o Page Registration and cut-off control.
o Folding center
2.2.6. Machine stopping Procedure (before going home)
 Remove any dropped sheets under machine.
 Keep all the production supporting tools and equipment in clean
condition and keep it in appropriate places.
 Collect the entire Reel shaft and keep it in proper stand at proper location.
 Blow air and clean folder sections.
 Rollers washing done with roller washing processor.
 Blankets cleaning done with recommended cleaning solution and
scrappers.
10
 Collect all weighed core ends and cut waste, wrapper waste in allotted
proper places.
 Switch OFF all machine room, chiller unit, and compressor room
lightings.
Reporting to HQ procedure
 At the end of every day production, all production related reports are sent
directly through our PROVEN Software system.
2.2.7. Plate fixing procedure
 Plate has to punch in punching machine.
 Plate has to bend in bending machine.
 Check the pagination, which plate belongs to which printing unit.
 Check for the color and make sure before fixing it.
 Fix the plate in the plate cylinder slot.
 Impression ON
 Inch the machine till it goes for one full round.
 Fix the gripper side of plate in the plate cylinder slot.
 Put off the impression.
2.2.8. Blanket fixing procedure
Tools required
 Torque screw driver: 4.5Nm.
 Hose pieces Diameter: 12 to 15 x 50 mm.
Blanket fixing procedure (T bar blanket fixing system)
 Put impression off
 Inch the print unit so that the blanket slot is easily accessible.
11
 Lock the machine by safe stop
 Loosen all screws evenly and remove the spacers & clamping bar.
 Clean clamping bar and lock up gap and preserve them with slushing
oil.
 Insert leading edge of the blanket into lock up gap and clam it with the
hose piece at both the ends of the lock up gap to ensure that the
blanket will not slip out of lock up gap while wrapping around the
cylinder.
 Release safe stop and slowly wrap the blanket onto the cylinder by one
cylinder revolution by pulling the free blanket end tight.
 Remove the hose pieces from lock up gap and pull the blanket
clamping bar of the lock up gap.
 Install the clamping bar such that the balls lock into place
 Insert both blanket edges into the grooves of the clamping bar and
immerse the clamping bar in the lock up gap.
 Put the screw from one cylinder side of the clamping bar into the
respective holes in the clamping bar and screw them approximately 2
revolutions into the thread.
 Start then from the center and screw the screws by approximately 1.5
revolutions in and adhere to the given sequence of (1, 2, 3…)
 Put impression on and inch the print unit by approximately 50
revolutions.
 Put off the impression.
 Lock machine by safe stop
 Start then from the center tighten the screws by torque screw driver to
max 4.5 Nm.
12
2.2.9. Blanket removing procedure
 Ensure the impression is in OFF mode.
 Inch the print unit so that the blanket slot is easily accessible
 Lock the machine by safe stop
 Loosen the clamping screws one after another by 3 revolutions each
 Remove the clamping bar by means of the two M5 screws: insert the
screws from top into the clamping bar and screw them tight.
 Remove the clamping bar and the blanket bar with the hose piece in
the lock up gap tight.
 Inching by one revolution. Carry on the free blanket end by hand wind
the blanket off the cylinder.
2.3 INKING UNIT
Ink duct / blade setting procedure
Ink zone screws of the ink zone adjustments must be adjusted such that
the ink blade closed does not have any contact with the ink fountain roller (gap
0.03mm).
Basic adjustment of key zone keys
 Close the ink fountain.
 Fill ink in (1/2 of filling amount) distribute the ink uniformly.
 Turn the ink fountain roller by handle or motor.
 Open the ink adjusting lever and insert 0.05mm filler gauge between ink
fountain roller and blade. Close the lever in the same zone and pull the
filler gauge, see that it can be pulled easily.
 Check your adjustment: the ink blade may not touch the ink fountain
roller.
 Clean and lubricate ink keys in every three months.
13
Scoring roller setting
Adjustment of the scoring roller with ink transfer roller
 Insert film between scoring roller and ink transfer roller at both ends.
 Set the scoring roller with transfer roller by rotating eccentric bush at O.S
and G.S. (0.10 for correct gap, 0.08 for go gauge, and 0.12 for no go
gauge).
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the eccentric bush with the help of socket set screw.
Ink transfer roller setting procedure
Adjustment of ink transfer roller with distributer roller
 Insert the film between ink transfer roller and distributer roller at both
ends.
 Set the transfer roller with distributor by rotating setting screws at both
ends.

Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the roller shaft with the help of hex.bolt and lock nut.
Ink distributer roller with rider setting procedure
 Insert the film between ink rider roller and distributer roller at both ends.
 Set the rider roller with distributer by rotating setting screws at both ends.
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the setting screws with the help of locking nut.
 Lock the roller shaft with the help of hex.bolt and lock nut.
14
Inner ink form roller with distributer roller setting procedure
 Insert the film between ink form roller and distributer roller at both ends.
 Set the inner ink form roller with distributor by rotating setting screws at
both ends.
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the setting screws with the help of locking nut.

Lock the roller shaft with the help of hex.bolt and lock nut.
Outer ink form roller with distributer roller setting procedure
 Insert the film between outer ink form roller and distributor roller at both
ends.
 Set the outer ink form roller with distributer by rotating setting screws at
both ends.
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the setting screws with the help of locking nut.

Lock the roller shaft with the help of hex.bolt and lock nut.
Ink form roller contact to plate cylinder setting procedure
 Mount the plate.
 Put the impression ON.
 Insert the film between ink form roller and plate cylinder at both ends.
 Switch ON ink form rollers on plate cylinder in manual mode.
 Rotate the respective turn buckles to achieve the desire pressure between
roller and plate.
 Lock the nuts of turn buckles.
 Switch OFF ink form roller and impression.
15
Checking of ink form rollers strip on plate
 Charge the roller train from ink fountain by manually ON in take-up
roller.
 Put the impression ON, inch the machine 12 - 15 revolution, inch the
press to optimum position, press safe stop.
 Switch ON the ink form rollers on plate cylinder in manual mode for 30
seconds and switch OFF.
 Switch OFF the impression, inch the press and check the ink strip on the
plate which should be throughout 4mm wide.
Blanket and rubber roller storage procedure
 Rubber rollers are must keep in roller stand in an air-conditioned room.
 Must be cover with polythene or paper duly powder coated.
 Blankets should be kept in air-conditioned storage and they should keep
in a rack or round shaped boxes made of plastic or corrugated.
 Blankets and rubber rollers must kept away from direct sunlight.
 Room temperature should maintain below 25 degrees.
2.4. DAMPENING UNIT
Contact between brush and water pan roller setting procedure
 Ensure the enough gaps between brush and pan roller in pneumatic
plunger OFF condition.
 Set the gap between brush roller and pan roller to 13.5mm adjusting hex
bolt at both ends.
 Check the gap by inserting setting gauge between pan roller and metallic
body of brush roller at both ends.
 Set until pulling force required to pull the gauge out of rollers in uniform
at both ends.
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 Lock the hex bolt by tightening the hex bolt at both ends.
 Switch OFF brush rollers.
Dampening form roller setting to chrome roller procedure
 Insert the film between damp form roller and distributor roller at both
ends.
 Set the form roller with distributer by rotating setting screws at both
ends.
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.
 Lock the setting screws with the help of locking nut.
 Lock the roller shaft with the help of hex bolt and lock nut.
Dampening form roller setting to plate cylinder procedure
 Ensure enough gaps between form roller and plate cylinder in pneumatic
cylinder OFF condition.
 Insert the film between damp form roller and plate cylinder at both ends.
 Put the impression ON in manual mode.
 Switch ON damp form rollers on plate cylinder in manual mode.
 Set until the pulling forces required to pull the film out of rollers is
uniform at both ends.

Lock the hex bolts by tightening hex bolt at both ends.
 Switch OFF dampening form roller and impression.
Plate punching, bending and fixing procedure
Plate punching device
Adjusting front stopper for plate width
 6 mm Allen key
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 Steel rule 1feet
 Steel rule 3feet
 Loosen the Allen screw of front stopper.
 Adjust the front stopper according to the plate width. The setting for the
front stopper is calculated by using following formula
A = [plate width + 419 / 2] + 3
 Reset steel rule to punch.
 Reset second steel rule to front stopper at right angle to first steel rule.
 Set front stopper at distance as per calculation of formula.
Punching single plate
 Bring the stopper in upper position with the help of hand wheel.
 Insert the plate in the punching device and move the leading edge towards
resting pins until it rests.
 Ensure the proper resting of plate with stopper and resting pin for correct
punching of plate.
 Turn the first hand lever to perform the punching operation.
 Removed the punched plate by turning the hand lever in its original
position.
Punching double page plate
 Bring the stopper in upper position with the help of hand wheel.
 Insert the plate in the punching device and move the leading edge towards
resting pins until it rest.
 Ensure the proper resting of plate with stopper and resting pin for correct
punching of plate.
 Turn the both hand lever to perform the punching operation.
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 Removed the punched plate by turning the both hand lever in its original
position.
Blanket under packing and fixing procedure
Blanket cylinder
 New rubber blanket thickness
1.95
 Under packing thickness
0.23
 Total thickness
2.18
 After rubber blanket subsiding
2.12
Blanket above the barrier after stretch 0.08 to 0.12 mm
Pasting the underlay foil
 Cut the underlay foil exactly to the required dimension.
 Put impression OFF.
 Inching to optimum operating position.
 Lay the underlay foil exactly parallel next to the lock-up gap and paste it
tight.
 Clamp the underlay foil by inching.
 Smooth out the underlay foil using a rag, starting from Centre and
smoothing it to both sides in order to remove bubbles.
 Pay attention to position of blankets, web and underlay foil. Do not
exceed the overlap of underlay over web.
Clamping the blanket for worm and worm wheel system
Tools required
 Blanket spanner
 6mm Allen key
19
Blanket fixing procedure
 Make the impression OFF.
 Inching to optimum operating position.
 Loosen the clamping strip by Allen key.
 Rotate the spindle by worm and worm wheel mechanism & achieve the
spindle position for fixing the blanket.
 Insert the front (leading edge) of the blanket.
 Rotate the cylinders by hand wheel.
Turn the unit in paper direction by hand wheel
 Always hold the tailing edge of the blanket in hand while turning the unit.
 Rotate the spindle again and achieve spindle position for inserting tailing
edge.
 Insert the tailing edge of the blanket.
 Rotate the spindle again to clamp the blanket
 Through impression ON.
 Inching by approx. 50 revolutions and lock the press by safe stop.
 Loosen the clamping strip & tight the blanket with recommended torque
by using blanket spanner.
Bustle wheel for fan out register control
The bustle wheel serves to compensate a cross web elongation caused by
dampening water absorption during the previous printing operation.
Compensator roller
The compensator roller serves the purpose of bottom unit to upper unit
registration matching. This roller is specifically required for tower print units.
Upper printing couples are equipped with compensator roller.
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Adjusting: Manual adjustment is carried out while the press is running.
 Turn the knob/handle of bustle wheel and compensator roller
o Turning clockwise
-
throwing - ON
o Turning anticlockwise
-
throwing - OFF
2.5. WORKING SYSTEM AND TECHNICAL PROCEDURES
2.5.1. Reel stand
Auto pasting procedure:
 Auto pasting is known as auto reel change for nonstop run of a press. It
can be operated through electrical clutch and break mechanism.
 According to various manufacturers the sequences can be changed for
minimum diameter reels. When the reel reaches a particular diameter
automatically go to the inner side of the auto paster for loading the new
reel for continue.
 This can be operated through cycles of brush, pasting and cutting
operations.
 After the pasting is completed the end core will remove from machine for
next pasting.
Side margin alignment procedure
 After pasting is completed side margin can be adjusted to the reference of
old reel or printing margin.
 To adjust the margin rotates the knurled knob provided on s1 for reel
adjustment.
 Towards operator side
= clock wise rotation.
 Towards drive side
= anti-clock wise rotation.
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Brake control procedure
 Brake is controlled by air pressure by reducing and increasing by
operating the air pressure regulator.
 For auto control of brake according to reel size the dancing roller is
provided and it will control the air flow from air pressure supplier
mounted on auto paster.
Infeed pressure setting
 The initial web tension is controlled by pressurized swinging roller and
the steel reel brake.
 In the second stage, web tension is measured and controlled in closed
loop manner with the help of load cell and driven infeed roller.
Adjusting set tension value
 Enter the desire tension value on the operator interface of tension control
system. The entered value will be displayed on the operator interface.
 Recommended value for set tension is 200 to 250 N which may vary
depending on the paper quality and printing material
 The actual value will be displayed and corrected instantly through close
loop system, thus maintain tension.
 At the time of printing, if we needed the operator can enter the new value
as per the need.
 Adjustment can be done while the press is running.
 The calibration of load cell to be carried out as per manufacturer’s
catalogue.
Paper path roll alignment
 Paper roll alignment can be done with dial gauge or measuring tape.
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 Parallel of roller should maintain.
Web break detection
The electronic web break detector monitors the paper. The paper is scanned
by a non-contact reflected scanner. In case of a web break the press is stopped
automatically. They are positioned right on the paper path. The distance
between the paper detectors is 40 mm. never run the press without paper
detector ON.
 To sense the web break on the machine, web break detectors are
provided on print unit and folder.
Web severer & inertia roller
 Two numbers of web severer and an inertia roller is provided per print
unit i.e. tower, H and mono. Web severer is positioned at entry and exit
of the web in print unit. Inertia roller is mounted on top of the unit.
 In case of a web break, the press is stopped automatically. Web severer
cuts the paper and paper is wrapped by the inertia roller to avoid paper
jamming in the cylinders.
2.5.2. FOLDING UNIT
RTF roller tension control procedure
Advance of collecting and former roller
 Adjustment is carried out
o Manually by adjusting variator gear drive with hand wheel
provided on S1
Manual adjustment
 Turn the hand wheel provided on S1 and adjust.
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 Advance:
o Turning clockwise
- increase the advance
o Turning anticlockwise
- decrease the advance
 The adjustment is indicated on the scale of the hand wheel, the PIV is
kept in positive +1 to pull all the web together to the required tension. It
optimizes the tension value between RTF roller and folding drum.
Former board cleaning procedure
 Former board cleaning can be done each completion of production.
 Cleaning agent like kerosene or other recommended product will be used.
NIP roller setting procedure
Tools required
o 16 mm DE spanner
o 12 mm slip gauge
 Always lock the press by safe stop while performing maintenance /
adjustment / lubrication or in case of guard opening.
 Throw the tension rollers off.
 Loosen the clamping screws on the roll lever and move the tensioning roll
by roll, lever to the desired width.
 Adjust the tensioning rolls at 12 mm distance from roller face in off
condition of tensioning.
 Retighten the clamping screw.
Draw roller setting procedure
 Insert a paper according to the product thickness which needed and rotate
the adjusting handle on both sides, until the paper pulling is smooth
without tearing the paper.
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Puncher needle changing procedure
Tools required
o 5 mm Allen key
o Special socket wrench.
o Setting gauge.
 Use a special socket wrench to unscrew the pins. Screw the new needle
pins and tight it on lever
Adjusting the needle pin height
 Turn the folding cylinder with the hand drive and bring the needle pins to
upper most position.
 Loosen the lever screw and adjust the needle pin height by using gauge.
 Adjust dimension - 7 mm from the cylinder body.
 Tighten the clamping screw of the needle pin lever.
Cutting roller fixing procedure
 Throw the cutting roll by turning the pneumatic hand control valve.
 Loosen the nut which secures the roll and safety cover by 18 mm DE
spanner.
 Remove the safety cover.
 Take out the slitting roll by pulling out
 Insert the new slitting roll and tight the nut. Assemble the safety cover.
Cutting knife changing procedure
 Always replace the both cutting knifes.
 Use 18 mm tabular box ring spanner,13 mm ring spanner
 Remove the cutting beam clamping screws and take out the beam from
cutting cylinder.
25
 Loosen the clamping bolts which secure the cutting knife.
 Remove worn cutting knife & insert new. Tighten the clamping screws
slightly.
 Adjust the cutting knife height reference to base by using adjusting screw.
Adjust height 45.5 ± 0.2 mm.
 Tighten the knife beam on the cutting cylinder and tighten with clamping
bolt.
 Ensure thick strip should always in running direction.
Cutting knife height checking procedure
 Adjust the cutting knife height reference to base by using adjusting screw.
Adjust height 45.5 ± 0.2mm
 Tighten the side screw fully.
Foam bar changing procedure
 Always replace both foam bars.
 Tools: 17 - 18 tabular spanner, 13 mm ring spanner.
 Remove the cutting beam clamping screws and take out the beam from
cutting cylinder.
 Loosen the clamping bolts which secure the foam bar.
 Remove damaged foam bar & insert new foam bars retighten the
clamping screws.
 Mount the knife beam on the cutting cylinder and check for proper fixing.
 Ensure thick strip should always in running direction.
Tucker blade height setting procedure
Tools:
o 10 mm DE spanner
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o 24 mm ring spanner
o Setting gauge
 Rotate the folding cylinder by hand drive and bring the tucker blade to
the accessible position.
 Remove clamping screws of three flaps and take them out.
 Loosen the tucker blade clamping screws.
 Adjust the tucker blade height to 29 mm from aluminium strip which hold
the blade.
 Tighten the blade clamping screws.
Gripper height setting procedure
 Gripper blade height should parallel to the cylinder outer surface.
Gripper pressure setting procedure
 Insert the product (paper) strip in between folding jaw plate & stop bar
and check the gap in SI & SII.
 It must be possible to pull the folder product off the closed folding jaw on
SI & SII with pressure.
 Check the adjustment of the folding jaws after each production changeover.
 The folding jaw gap shall only be as wide that the running copy does not
get out the place or slips off.
Cam position changing for 2 nd fold procedure
 Tools used: 13 mm DE spanner and 5 mm tommy rod.
 Loosen the M8 Hex clamping bolts of the opening cam fixed on SI of
gripper cylinder.
 Rotate the cam with the tommy rod toward reverse direction position up
to required position of jaw opening, in front of the delivery belt.
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 Lock the clamping bolts.
 Visually check for opening position.
Cam position changing for quarter fold procedure
 Tolls used: 13 mm DE spanner and 5 mm tommy rod.
 Loosen the M8 Hex clamping bolts of the opening cam fixed on SI of
gripper cylinder.
 Rotate the cam with the tommy rod toward reverse direction position up
to required position of jaw opening, in front of the delivery belt.
 Lock the clamping bolts.
 Visually check for opening position.
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CHAPTER 3
DINAMALAR MAINTENANCE PROCEDURE
3.1. MAINTENANCE
The basic principle of maintenance is to extend the useful life of an asset.
A proper Maintenance will improve the production capacity with only existing
capacity utilization. Maintenance is usually viewed, as a repair function of
maintenance is composite in nature. A wide range of activities are involved in
it. In fact maintenance keeps our entire system to be reliable, productive and
efficient. There is no definite maintenance procedure for a particular plant. It
varies from one plant to others.
3.1.1. Objectives of Maintenance
The principal objectives of maintenance activity are as follows
1. To minimize the breakage and maximize the plant availability
2. To extend the useful life of assets by minimizing wear & tear and
deterioration
3. To ensure the operational readiness of all equipment.
4. To ensure the safety of workers.
5. To establish a satisfactory working condition.
By systematic maintenance, it is possible to achieve Substantial savings in
money, material & manpower
3.1.2. Preventive Maintenance
Preventive maintenance is naturally carried out before any
interruption of production and major breakdown. This maintenance is
carried out in predetermined intervals.
Preventive maintenance will not only prevent the breakdown, but also it
will improve the output quality of the product, and condition of the machine.
This preventive maintenance is most successful one, and it is adopted in many
29
organizations. The best way to perform preventive maintenance consistently is
to develop operational checklists. The checklists should be designed with the
maintenance-activity steps in proper order for easy understanding. The
checklists should be initialed and dated by the person performing the
maintenance. Establishing maintenance checklists and procedures for each piece
of equipment maximizes the preventive maintenance program, and helps
accelerate training as well.
Advantages of Preventive Maintenance
1. Major repairs can be avoided.
2. Gives less production down time.
3. Product rejection is minimum.
4. Provides better quality control facilities.
5. Lengthens the life of equipment.
6. Provides safety to the workers.
7. Minimum inventory control.
3.1.3. Prediction Maintenance
Prediction maintenance takes preventive maintenance to a higher level.
Prediction maintenance utilizes more state of the art technology to predict when
equipment components will need maintenance before they fail. Major
maintenance and overhaul intervals are now being determined by scientific
methods and accurate data analysis. Prediction maintenance requires monitoring
specific elements that could cause catastrophic failure of the equipment.
3.1.4. Breakdown Maintenance
Breakdown maintenance is maintenance performed on equipment that has
broken down. It is based on a breakdown maintenance trigger.
Breakdown maintenance may be either planned or it can be unplanned. An
example of planned breakdown maintenance is run-to-failure maintenance,
30
while examples of unplanned maintenance include corrective
maintenance and reactive maintenance.
Breakdown maintenance can be more costly than preventative maintenance. A
summary of the extra costs of unplanned breakdown maintenance is included in
the reactive maintenance page.
3.2. MAINTENANCE SYSTEM FOR CTP
Figure 3.1 Computer to plate system
Do’s
 Staff should enter into CTP ROOM with neat and clean socks only.
 Uniform (coat) should be used immediately after entering the room.
 Room temperature should be maintained at 22 degree centigrade for both
CTP Room and Processor Room.
 CTP machines should not be switched on until the room temperature
reaches 22°C.
 In production time we must be used yellow light only.
31
 We should wear gloves, when we are handling plates both CTP and in
processor.
 Store room temperature should be maintained minimum at 21°C for all 24
hours. Alternate air conditioners can be used
 After production, loose packs should be kept in store room.
 Room should be cleaned weekly once under a supervisors guidance.
 Never allow any other person without management permission into CTP
room.
Production time
 Processor developer replenishes and gum replenishes level must be
checked before production in both available drums.
 Developer PH (11.96) should be checked before and after production.
 Weekly twice pre-wash roller and rinse roller should be cleaned.
 Monthly once processor should be cleaned. Change developer and gum
periodically.
 After every page arrival it must be checked for the page margin and date
line and then expose plate.
 After Every edition printing startup, first proof must be checked for date
line and imprint.
 If any problem raised in production time, it should be immediately
informed to the supervisor and take action.
Don’ts
 Never switch off the Air-condition at production time.
 Without gloves never handle plates.
 Never use pen dive or CD/DVD in CTP room computers.
 Never change/edit ripping setting in ripping server.
32
 Never switch on normal white light during production time.
CTP Room maintenance
 Room maintenance as dust free room.
 Staffs enter in room without shoes and wear clean socks.
 Room cleaned weekly once.
 CTP plate wrapping sheets keep in dustbin and disposed daily after
complete the production.
Wiring safety
 Wiring done with UG cable, flame guard wire concealed with CONDUIT
pipe under wooden platform.
 Every one meter tagged with wire tag.
 Outer position of cables covered by spiral hoses.
Processor cleaning procedure
 Weekly twice prewash rollers and rinse roller should be cleaned.
 Monthly once processor should be cleaned. Change developer and gum.
 Monthly once filter also changed.
3.3. MAINTENANCE SYSTEM FOR MACHINE
Machine Cleaning Procedure
Printing Units:
 First we clean the path roller with iron brush
 The path roller has to clean by compressed air.
 All ink devices has to take out clean and put back.
 All plate cylinders have to clean.
 Inside body of machine has to clean.
33
 If there is schedule for brush cleaning, has to clean the brush.
 All paths have to clean.
Reel Stand
 Reel stand has clean by compressed air.
 Reel has to clean by cotton waste using diesel.
 The entire platform has to clean.
 Machine body has to clean.
 Check the rotation of the reel arms.
 Check the reel lateral adjustment knob & stud condition monitoring for
free rotation.
 Check the both reel loading brake pads condition for a proper web
tension.
Electrical
1. Daily:
 Cleaning auto pasting sensor and its reflector.
 Checking working condition of reel stand arm.
2. Weekly:
 Electrical DB side general cleaning and preventive maintenance.
3. Monthly:
 General clean and preventive maintenance of tension control motor
and reel arm motor
Roller Washing Procedure
 Washing the rollers is permitted only without web lead and at low speed.
 Interrupt ink supply from ink fountain to inking unit.
 Shut the ink keys in zero position.
 Throw the ink take off roller off using the operator interface OPT1.
34
 Start the press line in run mode at 2000/3000 IPH.
 Throw on the washing blade using the hand lever.
 Stop press line by press Technical rundown stop button.
 Lift the washing tray from the stud bolt and take it out to cleaning.
 Insert the washing tray and check it for proper seat.
 The washing blade removed, cleaned and positioned at off condition.
Ink Duct Cleaning Procedure
 Remove the ink from the ink duct.
 Rotate the ink fountain roller for cleaning.
 Press the button of the respective ink duct in % up for fast run of the duct
roller.
 Set the ink zone keys to zero.
 Switch the ink fountain roller off.
 Remove the ink.
 Loosen the knurled nut.
 Lift the locking level bolt.
 Tilt the ink fountain carefully and rest it on resting pins.
 Clean the ink fountain then tilt the ink fountain up carefully approach in
the reverse order.
Folder
 First clean with compressed air.
 Finger guards remove clean and put back.
 RTF rollers have to clean.
 Clean all cylinders.
 Clean former board.
 Clean quarter fold.
35
 Conveyor belts
 Check the draw nip roller pressure setting monitoring by single web.
 Check the cutting knife & foam bar condition.
 Check the catching pins condition for a product width.
 Check cam & cam follower lubrication monitoring daily.
 Check front dropping belts & delivery conveyor belts.
 Check the tucker blade & gripper blade condition for proper delivery.
Electrical
1. Daily:
 Cutoff control all motor working condition to be checked.
2. Weekly:
 Electrical DB side general cleaning and preventive maintenance.
3. Monthly:
 Folder oil pump motor and its control side general cleaning and
preventive maintenance.
Stacker
 First clean with compressed air.
 Clean all conveyor belts.
 Clean all console.
Ink & Dampening Maintenance Procedure
Daily: check temperature, conductivity, PH value and alcohol content.
Weekly cleaning: solution tanks and pans for optimum water receptivity
 Drain system pans, lines and tanks. Refill with hot water.
 Add prepared dampening system cleaner, and pump into pans to circulate.
36
 Maintain flow of cleaning solution through system until only
discoloration of the solution is visible, and no large particles are left.
 After system is clean, drain, flush with clean water, drain, and wipe out
pans and tanks.
 Change all filters before refilling with dampening solution.
 Before dampening solution is pumped into pans clean all damper rollers
and etched chrome rollers.
 Desensitize roller surfaces by cleaning and etching them (rubber, chrome
and ceramic rollers).
Refresh dampening water: each 2 weeks for alcohol-free solution; each four
weeks for IPA solution.
Annual Maintenance:
 Empty the dampening system and remove all filters.
 Sufficiently fill the reservoir with cleaning solution to ensure a smooth
circulation.
 Circulate 2 or 3 hours. (turn off freezer unit and run warm whilst
cleaning)
 Empty the reservoir and rinse with water for at least 10 minutes.
 Re-empty the reservoir and rinse with water and 2.5% of dampening
solution additive.
 Empty the reservoir and re-fill with dampening water, ready for use.
Common Maintenance Related Problems in Dampening System
Dampening solution is not circulated (or low flow rate)
Blocked
filters (feed pump inlet or between pump and heat
exchanger).Incorrect pump direction or insufficient power. Check phase rotation
37
of pump motor and change if necessary. Dampening solution level inside the
tank is too low: check fresh water supply and clean fresh water inline filter.
Air cooling not working:
High pressure malfunction: clean condenser plates and ensure free air
flow throughout the unit; verify room temperature is not over 40°C/104°F. Press
reset button on high pressure switch.
Water cooling system not working:
High pressure malfunction: ensure circulation of chill water is correct and
filter is cleaning; verify chill water inlet temperature is about 25°C/77°F. Press
reset button on pressure switch.
Additive dosing system not working:
Interruption of fresh water supply: check additive dosage mode is
activated; clean fresh water inline filter; ensure fresh water supply pressure
(min. 1 bar/26 GBH) and flow rate (min. 100l/h /14.7psi). Interrupted additive
supply: blocked foot filter at the end of the suction pipe or insufficient additive
in container.
Too low alcohol level in dampening solution:
Check if alcohol in dosage mode is activated; blocked foot filter at the
end of the suction pipe; insufficient alcohol stabilizer.
Too high alcohol rate in dampening solution:
Dirty or broken alcohol supply solenoid valve.
38
Folder Maintenance
Clean mechanical elements:
Clean the mechanical elements, sign and indicator lights. The
accumulation of dirt and debris is a major cause of unscheduled stops and
malfunction. Debris build-up on former and turner bars is a frequent cause of
creasing leading to web breaks. Use an industrial vacuum cleaner daily to
eliminate dust and debris.
Sensor:
Clean the folder jam and web break detectors.
Cutting cylinders:
Check knives and block (folding blade and rollers, cutting rubber, jaws,
knife pins). Follow the manufacturer’s instructions for set-up and replacement
parts. Adjust collecting or tucker blade cylinders diameters correctly.
Slitter:
Poor cutting leads to jams. Ensure the assembly is correctly set and blade
sharp (the correct blade setting should be just contact-free from the cutting
block).
Clean conveyor components:
Ensure belt, tape roller, tension pulleys are correctly set. Replace when
worn or damaged.
Lubrication system:
Follow manufacturer’s recommendations. Check oil level and filter,
change at specified intervals.
39
Jaw cylinder brushes:
Check for wear and damage.
Folder tapes:
Check for wear and damage and tension.
Belt delivery tapes:
Check for wear and damage and tension.
Safety devices:
Check that mountings are secure, correctly aligned and complete.
Delivery fan and stepping wheel:
Dirty, damaged or incorrect adjustment may result in a jam.
Folder guides:
Check dimensions against the reference dimensions.
Timing belt:
Check tension, inspect for wear, damage and oil contamination.
Disc brakes:
See manufacturers schedule. Check thickness of pads; inspect for wear,
damage and oil contamination.
Stacker Maintenance
Clean and check routine:
A clean machine ensures correct set-up, reduces wear and makes trouble
shooting more efficient.
40
 Daily removing the paper scraps from inside and under machine to
avoid jams and component malfunction.
 Use clean soft rags only to clean conveyor belts.
 Clean the lenses of all optical sensors and reflectors.
Belts:
Check that belts are centered on the guide rollers with tension that
ensures consistent signature transport and that belt splices are in good condition.
Air system: Check for leaks.
 Leaks are invisible and odourless and their hissing sound is often lost
in background noise.
 Use an ultrasound unit to locate and fix air leaks.
Chains:
If the chain tensioners do not maintain correct tension this will strain the
sprockets and the transport will become inconsistent .Have a high number of
mechanical parts and links that require frequent lubrication and cleaning to
prevent failure.
Air filters:
 Clean and change regularly.
 Check oil levels daily, open and drain water condensation valves and
listen for abnormal noises or vibrations.
 Weekly, check air pressure and contamination indicator if fitted, clean
or replace air filters (filters are available to remove both moisture and
oil vapor from the incoming air).
 Check safety and relief valves.
 Monthly inspect compressor and hoses for leaks.
41
 Change oil and inspect for contamination.
 Check rust and corrosion.
 Record noise level.
Control console electrical cabinet:
Vacuum clean interior (never use compressor air) and clean or replace the
filters. Correct cleaning (with power off) prevents overheating and extends
component life.
Lubrication:
Always follow the supplier’s instructions as this will prevent premature
wear and malfunction. Correct oil level in the central lubrication system protects
against premature wear and prevents excessive noise. Change oil at
recommended intervals.
Component wear is caused by abrasion, corrosion and direct metal to
metal contact. Correct lubrication will reduce wear and prevent failures. Over
and under lubrication is a major threat to component life and seals.
 Use a systematic lubrication schedule (with a clear responsibility) using
only the recommended lubricant.
 Ensure grease guns and oil cans are the right type, work properly and
lubricant is clean. Consider colour coding lubrication points and their
matching grease guns/oil cans.
Lubrication
For bearer:
 Lubrication ON timing
- 1 – 5 sec.
 Lubrication OFF timing
- 1 – 5 sec.
 No. of lubrication cycles
- 1 – 5 Nos.
42
 Recycling time
- 60 – 3600 sec.
For bush
 Lubrication ON timing
- 1 – 5 sec.
 Enter lubrication ON/OFF timing as per the requirement.
Hand Pump Oil Lubrication (O.S.)
Manually operated oil pump is provided for operator side lubrication.
This covers all bushes of operator side.
 Check filling level at view glasses of oil pump at operator side.
 Manually operates the hand pump 2 – 3 times after eight hours.
Refilling oil
 Open the oil filling cap.
 Fill oil in oil sump, upto the oil level indicator.
 Drain oil from all lubrication points and collected it in the special plastic
container, dispose off it according to the relevant environmental
instructions.
 Do not use kerosene or any solvents for cleaning.
Lubricating the cylinder bearings
Grease gun
 Lubrication the bearing on operating side through lubricating nipples.
 Gear side cylinder bearings are oil lubricated through gear pump.
Prohibited cleaning agents for cylinder surfaces
The following agents are not allowed to come into contact with cylinder
surface.
43
 Chromatic acid (of any kind)
 Phosphoric acid (of any kind)
 Nitric acid (of any kind)
 Sulphuric acid (of any kind)
 Hydrochloric acid (of any kind)
 Hydrogen peroxide
 Citric acid (concentrate)
 Acetone
 Fluoric acid
 Chlorine
 Tartaric acid
 Lactic acid
 Stearic acid
 Vegetable acid
3.4. MAINTENANCE SYSTEM FOR COMPRESSOR
There are three compressors in Dinamalar press
Compressor 1
 Company name
: Atlas Copco
 Product type
: GA 30 VSDFF
 Maximum final pressure
: 12.75 BAR
 Free air delivery
: 58 l/s
 Motor power
: 30 KW
Compressor 2
 Company name
: Atlas Copco
 Product type
: GA 18 FF
44
 Maximum final pressure
: 10 BAR
 Free air delivery
: 45.1 l/s
 Motor power
: 18.5 KW
Compressor
 Company name
: Atlas Copco
 Product type
: GA 11 FF
 Maximum final pressure
: 13 BAR
 Free air delivery
: 20.2 l/s
Calculating compressor pressure
Compressor pressure measured at CFM (cubic feet per minute)
Example:
1 KW
= 1.34 HP
11 KW
= 1.34 × 11
= 14. 74 HP
1 HP
= 3.9 CFM
11 KW
= 14.74 × 3.9
=57.486 CFM
Daily checkup:
 Oil level has to check.
 Cleanliness of the filters has to check.
 Working condition of auto drainer has to check.
 Working condition of the dryer system.
45
Weekly schedule:
 The entire filter has to clean.
 V-belt tension has to check.
 Electrical equipment visual checkup has to do.
 Compressor general cleaning.
Periodical maintenance:
 Every 3000 run hour’s air filter has to change.
 Every 3000 run hour’s oil filter has to change.
 Every 6000 run hour’s oil separator has to change.
 Every 6000 run hour’s oil has to change.
 Every 3000 run hour’s V belt condition has to check.
 Every 3000 run hour’s electrical equipment has to check.
 Every 12000 run hour’s valve kid assembly have to change.
Auto Drain System
 Air compressor having in-built auto drainers in it, in this drainer there is
no timer set point for time interval & operating time for drainer, it works
by mean of there is a sensor inside the drainer for sensing the water
formation in the air pipe line if the water reaches the sensing point mean
automatically the drainer will drain the water from the pipe line.
Reservoir Tank Auto Drain
 There is one more separate auto drainer connected in our air Reservoir
tank side, this drainer is having separate timer set points for time interval
& operating duration, the drainer having the set points of 0.5 min to 45
min time interval & 1 to 10 sec for operating time. In this we set to 30
min time interval & 5 sec operating time.
46
3.5. MAINTENANCE SYSTEM FOR DIESEL GENERATOR
General Information
 Make
`
: Kirloskar
 Rating
: 400 KVA
 Rated voltage
: 415 volts
 Engine model
: DV8
 Engine serial number
: 52.05231
Figure 3.2 Diesel generator
DG daily routine check-up procedure
 Check the engine oil level in the level gauge. Oil mark should be
indicating maximum level in level gauge. If any deviation top up the oil
level to maximum
 Check the coolant level in radiator side.
 Check the fuel level into the diesel service tank. Minimum 50% of fuel
should be available in the service tank.
 Check the belt tension, all Hose clip tightness check -up.
 Check the battery voltage on the alternator panel. Battery voltage should
be in 23V to 26VDC.
 Check the battery Distilled water level.
47
 Check the external leakages of oil, fuel and coolant.
 Check the control panel display alarm signals.
 Daily 10 minutes run the DG set for ideal run.
DG Periodical Maintenance Procedure
 ‘B’ checks kit should be changed every 300hrs of DG.
 Change the DG Engine oil every 600 hrs once.
 Check the battery terminal and clean the terminal.
 ‘C’ check kit should be changed every 300hrs of DG.
 Check the alternator cable terminal tightness.
 Check the AVR connecting terminals.
 Check the copper slip ring and carbon shoes status.
 Check the all gaskets leakages.
 Check the radiator internal cooler service.
 Check the radiator cooling fan motor condition.
 Check and clean the all sensor (water level, oil temperature, RPM sensor)
if necessary.
 Check the self-motor, Dynamo working status.
 Change all the belts in every 2000 running hours or once in a year.
 Check the including daily check list.
DG Diesel Consumption and Measurement
 Check the fuel level into the diesel service tank. Maximum 50% of fuel
should be available in the service tank.
 Fuel consumption based on the Load & Running hours of the DG set.
 Fuel consumption & measurement will monitor in the panel display unit.
 Now actual consumption of DG is 3.8 Unit per liters on full load.
48
3.6. RO PLANT MAINTENANCE
Figure 3.3 RO Plant
Raw water
Membrane
Softener
Filter
RO plant
(Sand filter first stage)
Softener
tank
 Backwash the sand filter for 10 minutes every day.
 Rinsing the sand filter for 5 minutes every day.
 Check the water level in the softener tank before switching on the R.O
plant.
 Switch on the R.O plant. Then slowly increase the pressure up to 7.5 to
8.5 kg/cm².
 The pressure in the R.O plant should be in the range of 1.5 to 12.5
kg/cm².
 Regenerate the softener plant twice in a week.
 Clean the softener plant strainers once in a week.
 Change R.O plant micron filters once in two weeks.
49
 Chemical service should be done in the sand filter, softener and the R.O
plant has every 4 months once.
 After the R.O water production starts then check the PH value. The range
should be between 6.5 to 7.0
 Check the TDS of the R.O water .The range should be 80 to 150 PPM.
For Chiller Tank
 Check if all the water trays are cleaned in the printing machine.
 Check if the water stoppers are properly positioned in the trays.
 Check the water flow in all water trays.
 Check if the PH of the water in the range of about 4.8 to 5.5.
 Check if the conductivity of the water in the range of about 800 to 1400.
 Check if the temperature of the water in the range of about 18 to 25°C.
 Check the working condition of the return water accumulation tank
motor.
 Check the working condition of the WLC (water level controller) and the
sensors of the accumulation tank motor.
 Check the working condition of Dosatron and the percentage.
 Clean the return line micron filters every day.
 Change the chiller tank water once in a week.
 Clean the printing machine water pipe lines 3 months once.
50
3.7. FOUNTAIN SOLUTION
Fountain Solution Doser
DOSATRON Water Power Dosing Technology 2.5 m³/h – 11 GPM
DOSATRON procedure
Installed directly in the water supply line. The DOSATRON operates by
using water pressure as the power source. Water activates the DOSATRON
which takes up the required percentage of concentrate. Inside the DOSATRON
concentrate is mixed with water. Water Pressure forces the solution downstream
the dose of concentrate will be directly proportional to the volume of water
entering the DOSATRON. Regardless of variations in flow or pressure which
may occur in the main line.
Type of fountain solution
For conventional news printing – NEWSFOUNT plus 1388
For UV news printing – Press AID+ liquid gold CSUV
Maintenance
 Rinse the injection areas after using the DOSATRON. To do this insert
suction tube in to container of clean water ( ̴ 1 liter (0.264 US
GALLONS))
 Routine maintenance once a year will add to the life of your
DOSATRON – replace the dosing seals as well as the suction tube
annually to ensure proper injection
51
Figure 3.4 Dosatron (Fountain Solution Doser)
 Water:
The largest component of fountain solution is water. It is very important
that the water used be as free from impurities as possible.
 Gum:
Gum Arabic is used in fountain solution to desensitize the non-image area
of the plate.
 Corrosion inhibitor:
Magnesium nitrate is used as corrosion inhibitor to prevent the oxidation
of printing plate.
 Wetting agent:
Glycol, glycol ethers combination with ethylene used as a wetting agent
to reduce the surface tension of the fountain solution. In other words it
quickly spreads on to the plate surface when it is applied by dampening
system of the machine.
52
 Antifoaming agent:
Avoids the fountain solution to foam or bubble, which cause distribution
problems on press.
Flow line Maintenance
The saddle stitches SS6 stitch star, designed to meet the needs of modern
bindery which performs with an automatic stitching line with 10 feeders and
inline three knife trimmers.
Simple maintenance and quick make-ready of stitching heads, assured
reliable and efficient production.
Simple timing of gathering chain to the stitches.
Bearing supporting the gripper bar provides precise book transfer and extends
gripper bar life. Maintenance-free steel capped gathering chain and chain rails.
Easy access feeders with superior control
 Each feeder has adjustable gripper and vacuum opening.
 In the horizontal format, feeders can be loaded easily and quickly.
 Signature racks provide quick identification and verification of proper
signature loading.
 Clear protective covers on each feeder allow safe, easy monitoring.
 Production indicator light towers at each feeder and a completely visible,
full length catch tray beneath the feeders allow easy monitoring of
production.
 Cards and inserts can be fed without additional attachments.
Easy maintenance, heavy duty three-knife trimmer
 The guards are vertically raised to allow convenient access from all sides.
53
 Hand wheel adjustments on the three-knife trimmer enable quick makeready.
 Lubrication is quickly accomplished from a central dispensing pump
through copper tubing. External lubrication fitting and sealed bearings
throughout the saddle stitching system also make maintenance easy.
 Knife changes are quick and easy.
 It can be accessorized with a 4th knife (optional).
 Finished booklets exit on the tray from the delivery end.
Efficient high speed production
 The stitches can be equipped with up to twelve independently controlled
feeders.
 Outstanding features provide quick and simple make-ready and
changeovers with minimal material spoilage.
 Rated speed at 8000 cycles per hour.
Safe operation
 Electrical interlocking safety guards are installed on the machine with
clear protective covers on each feeder.
 Quality and safety standards are affirmed.
54
CHAPTER 4
WASTAGE REDUCTION ANALYSIS
4.1. INTRODUCTION TO NEWSPAPER PRINTING
Newspaper printing is a highly specialized job that only a special
newspaper printing press can handle. Since newspapers are printed on a daily
basis, a newspaper printing press needs to work constantly to keep up with the
daily schedule. There is no virtually no room for delays. Meanwhile effective
usage of consumables and machinery plays a crucial role in newspaper printing.
4.2. PAPER MANUFACTURER DETAILS
o Sri Venkateswara papers.
o Servalakshmi paper and board.
o GVG paper mills limited.
o Sri Harikrishna papers
o TNPL news print
o Sun papers
o Hindustan
o Tasman
o Kondapova
Paper imported from various countries such as France, Korea, Canada, China,
Russia and New Zealand.
4.2.1. Need for importing paper
Basically one paper manufacturing company can’t fulfill all the
requirements of news printing press in all the 12*30 days, due to various
reasons such as natural disaster, transportation delays etc.
55
The paper is ordered in thousands of tons and it can be ordered in
such a way that the value of Indian money against the foreign currency is high
and it obviously changes every day according to the world trade market, so it is
necessary to be up to date with the economic situation of the global market and
the paper cost
4.3. PAPER WASTE REDUCTION
Paper waste reduction must be done in order to increase the profit of a
company. Normally, wastage gets increased due to inefficient practices carried
out in an industry. It is also obvious that there are some wastes which are
irreducible and they need to occur. Waste reduction is the major parameter to be
maintained in a consistent manner for cost effectiveness in production.
Paper is the highest cost component for a Newspaper Printer, and we can
easily classify the total paper waste in a press by taking difference of Newsprint
supplied to the press and total sellable copies printed, the difference is the net
waste.
In order to effectively manage waste in a press, let us look at further
classifications and then dwell on process and areas where we can monitor,
control and manage waste. To do this effectively, details about the paper was
looked at.
4.3.1. Newsprint Waste and Its Classification
In order to effectively manage paper wastage in a press, paper wastes are
initially classified and then studied in a detailed manner so that process can be
monitored, controlled and managed. Paper waste reduction can be broadly
classified into two categories namely printed waste and non-printed waste.
56
Print waste
Printed sheets that affect the readability and do not satisfy the quality
requirements are considered printed waste. Print waste depends on the
effectiveness of the machine used, consumables and skill quotient of the
employees which is interrelated in a complicated manner.
Non print waste
Wastes that are obtained before printing are called non-printed wastes. It
includes wastes that occur from reel warehousing till splicing the reel.
There are three important inevitable non printing wastes in any
newspaper press namely,
1. Wrapper waste
2. Matt waste
3. Core waste
Wrapper Waste
Reels are sealed with a wrapper and details regarding paper are furnished
in the wrapper. Before fixing the reel into machine, wrapper has to be removed
and some layers of paper materials get to be reduced. Such waste is called
wrapper waste.
Matt Waste
Reels get damaged on the outer surface while transporting and handling.
Thus before printing, damaged portion of the reel is peeled off. Such waste is
called matt waste.
57
Core Waste
Certain portion of the reel is left unused along with the core, which
cannot be used for further printing in the machine. Such wastes are considered
as core waste, it various from machine to machine.
NEWSPRINT WASTAGE ANALYSIS
wrapper waste
17%
print waste
43%
cut waste
13%
core waste
27%
Chart 4.1 contribution of different waste
4.3.2. Significance of waste reduction
Waste reduction (or prevention) is the preferred approach to waste
management because waste that never gets created doesn’t have waste
management costs. Waste reduction also helps conserve resources for future
generations and contributes to a cleaner environment. In general waste
management constitutes three important methodologies (i.e.) Reduce, Reuse and
Recycle.
4.3.3. Reasons for different waste
A press which is ignored for preventive and routine maintenance by the
press crew will obviously generate higher waste. The operators and maintenance
58
staff should understand the press well; they must be trained by the supplier.
Normally the focus is on production and as long as the crew is able to deliver
production machine problems are ignored, deficiencies are patched up which
subsequently result in break downs or excessive wear and tear of critical
components directly effecting print quality and generation of non-sellable
copies. A good printer will understand that any deficiency in print quality may
have originated from a dormant press problem which is being overlooked.
Though a web offset printing press prints on one continuous roll of paper,
each part of the press is not running at the same speed. In order to maintain
tension, each component has nip points that drive the web at different speeds in
order to control web tension. These differences are marginal, but crucial for
each part of the machine to be able to perform its function.
Wrapper is the outer covering of the reel which carries the details of the
reel. It should be peeled of before printing and hence considered as waste.
Matt waste is due to handling and transportation of the reel.
4.3.4. Comparison of 3R’s of waste management
Reuse of products may not satisfy the quality expectations of the
customers. Though recycling is considered as eco-friendly, it requires time,
energy and money but the fact of the matter seems to be less effective in terms
of quality as far as paper is concerned. While examining the ground realities of
the three methods in reduction literally there is no additional expenditure
incurred instead it requires constant monitoring and cautious approach of the
management.
Source of variables in printing
 Material: paper, ink, adhesive.
 Men: skill, proficiency, application, physical condition, mental condition.
59
 Machines: manufacturer, wear and tear, interactions between human and
machine.
 Working conditions: temperature, RH, paper, fountain solution, pH,
lighting.
Statistical process control

Statistical process control is a method of using analytical techniques and
tools to interpret data derived from process measurement. This makes it
possible to understand the process capabilities and variables. The ultimate
purpose of the statistical process control is to remove all variability from
the process and make it totally predictable.
Statistical process control tools
 Pareto analysis
 Cause and effect diagram
Pareto analysis
Pareto analysis is a statistical technique in decision making that is used
for selection of a limited number of tasks that produce significant overall effect.
It uses the Pareto principle – the idea that by doing 20% of work, 80% of the
advantage of doing the entire job can be generated. Or in terms of quality
improvement, a large majority of problems (80%) are produced by a few key
causes (20%).
It involves steps namely,
 Listing the cause and their frequency as a percentage.
 Arrange the rows in the decreasing order of importance of the causes. (i.e.
most important cause first)
 Add a cumulative percentage column to the table.
60
 Plot with cause on x-axis and cumulative percentage on y-axis.
 Join the above points to form a curve.
 Plot a bar graph with cause on x-axis with percentage frequency on yaxis.
Cause and effect diagram
 Cause and effect diagram are used to break down a process into the major
categories that affect the process. These include the environment, people,
materials, method, measurement and machines. These six areas define all
the possible causes of process variation. Cause and effect analysis is a
natural step between flow charting and the actual gathering of data. This
tool can be used in all areas of an organization, not just the manufacturing
or production cycle. Applications range from identifying quality to
ensuring well trained and well educated employees.
 Cause and effect diagram is actually divided into two elements. The right
side of the diagram normally states the effect or problem element of a
process. The left side of the diagram states the causes of a lack of
improvement. Once the cause and effect of process variables are known,
it is possible for a worker to keep the process operating in a manner that
only produces acceptable components or products. Cause and effect
diagram can be used as a visual continuous improvement tool.
 The management must ensure that all the employees are educated in the
need for quality and given the appropriate tools to accomplish the
requirements of their jobs. Allocate financial support for initiating and
maintain statistical process control as part of the total quality control
process.
61
4.4. REASONWISE WASTAGE COPIES (NEWS LINE 45)
For January
18
16
14
Percentage
12
10
8
6
4
2
0
Web
Auto
Auto
Web
Break Pasting
Pasting
Joint
Break
Failure
Copies
Reel
percentage 15.38
14.74
12.95
9.84
Air
Tube
Burst
5.16
Blanket Registr
Folder Power
Plate Electric
Cleanin ation
Jam Failure
Change al Fault
g
Out
5.09
6.83
8.4
9.41
8.16
3.97
Chart 4.2 cause and effect diagram for news line 45 – Jan 2015
For February
25
Percentage
20
15
10
5
0
Auto
Web
Auto
Blanke
Pastin
Regist Plate Power Plate
Air
Break
Pastin
t
Web Folder
ration Chang Failur Scum Tube
g
Break Jam Cleani
- Joint
g
Failur
out
e
e
ming Burst
Reel
Copies
ng
e
percentage 21.65 14.15 11.96
8.8
8.6
4.34
6.65
5
6.3
4.28
8.23
Chart 4.3 cause and effect diagram for news line 45 – Feb 2015
62
4.5. REASONWISE WASTAGE COPIES (CITY LINE EXPRESS)
For January
40
Percentage
35
30
25
20
15
10
5
0
percentage
web break
auto
pasting
failure
auto
pasting
copies
folder jam
power
failure
35.15
22
23.04
10.39
9.4
Chart 4.4 Cause and effect diagram for city line express – Jan 2015
For February
60
50
Percentage
40
30
20
10
0
percentage
Web Break
Auto Pasting
Copies
Auto Pasting
Failure
Web Break joint reel
Folder Jam
54.33
18.18
10.38
10.99
6.1
Chart 4.5 Cause and effect diagram for city line express – Feb 2015
63
4.6 WASTAGE CONTROL ANALYSIS
4.6.1. WASTAGES AND PRODUCTION EFFICIENCY IN PROJECT
DATE
CITY LINE EXPRESS
Date
Web
Total
break no of
NEWSLINE 45
Production Down Web
efficiency
copies wastag
Total
time
break no of
(min)
copies wastag
e
e
copies
copies
Production Down
efficiency
time
(min)
Jan 23
145
1548
85.45%
40
-
1632
92.59%
10
Jan 30
355
1806
41.94%
90
224
1578
96.72%
10
Jan 31
344
1996
68.52%
85
432
2500
76.59%
48
Feb 06 336
1588
78%
55
434
1958
96.02%
35
Feb 07 260
1141
81.08%
35
673
3551
70.59%
75
Feb 13 224
1663
78.95%
60
-
2683
61.08%
72
Feb 18 -
1311
82%
45
-
1636
90.91%
10
Feb 20 476
1963
71.43%
80
250
2275
67.22%
59
Mar 06 381
1638
86.54%
35
-
2962
59.44%
73
Mar 20 -
1525
77.36%
60
230
2325
80.56%
35
Mar 21 246
1609
68.97%
90
470
2170
79.38%
33
Mar 27 120
1760
82.26%
55
-
-
100%
0
Apr 03 -
2131
66.67%
115
616
2267
79%
42
Table 1. Wastage and production efficiency in Dinamalar press
64
City line express
Web break
30
Percentage
25
20
15
10
5
0
23-Jan- 30-Jan- 31-Jan- 6-Feb- 7-Feb- 13-Feb- 20-Feb- 6-Mar- 21-Mar- 27-Mar15
15
15
15
15
15
15
15
15
15
web break 9.36
19.08 17.23 21.15 22.78 13.46 24.24 23.26 15.28
6.81
Chart 4.6 Paper waste due to web break in city line express
News line 45
Web break
30
Percentage
25
20
15
10
5
31-Mar-15
27-Mar-15
23-Mar-15
19-Mar-15
15-Mar-15
11-Mar-15
7-Mar-15
3-Mar-15
27-Feb-15
23-Feb-15
19-Feb-15
15-Feb-15
11-Feb-15
7-Feb-15
3-Feb-15
30-Jan-15
0
30-Jan- 31-Jan20-Feb- 20-Mar- 21-Mar6-Feb-15 7-Feb-15
3-Apr-15
15
15
15
15
15
web break 14.19
17.28
22.16
18.95
10.98
9.89
21.65
27.17
Chart 4.7 Paper waste due to web break in news line 45
65
4.6.2. REASONS FOR INITIAL WASTAGE:
 Dirty water tank
 Improper PH, conductivity
 Improper water temperature
 Water with bad smell
 Water tubes with fungus
 Improper side margin
 Improper head margin
 Improper registration control
 Improper communication in CIP3
 Improper ink water balance
 Improper paper tension control
 Improper plate fixing (transpose of a plate)
4.6.3. START-UP WASTE ANASLYSIS FOR JANUARY 2015:
INITIAL WASTAGE
DATE
CITYLINE-35
NEWSLINE-45
01-01-2015
1687
2742
02-01-2015
1881
2462
03-01-2015
1017
2296
04-01-2015
1942
3383
05-01-2015
2092
1739
06-01-2015
1954
2505
07-01-2015
1727
1478
08-01-2015
1888
1988
09-01-2015
1799
2482
10-01-2015
2176
1567
66
11-01-2015
1585
3431
12-01-2015
1874
1773
13-01-2015
1906
2650
14-01-2015
3376
2198
15-01-2015
1885
1971
16-01-2015
1640
1876
17-01-2015
1279
2532
18-01-2015
1890
3646
19-01-2015
1752
1516
20-01-2015
1821
2335
21-01-2015
1900
1805
22-01-2015
2429
1661
23-01-2015
1675
2536
24-01-2015
1802
1236
25-01-2015
1050
4201
26-01-2015
2432
1810
27-01-2015
1963
2451
28-01-2015
1846
1614
29-01-2015
1806
2027
30-01-2015
2022
2664
31-01-2015
1881
1200
TOTAL
57977
69784
Table 2. Initial waste analysis for January
67
Startup initial wastage analysis (city line express Jan 15)
3600
3400
3200
3000
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
wastage copies
management expectation
Graph 1. Initial waste analysis for city line express
Startup initial wastage analysis (News Line 45- Jan 15)
4600
4400
4200
4000
3800
3600
3400
3200
3000
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
wastage copies
management expectation
Graph 2. Initial waste analysis for news line 45
68
CALCULATIONS:
FOR CITYLINE-35
Average wastage = Total No. of. Initial copy wastage
Total No.of. Days in a month
Wastage more than management expectations = Daily wastage in average Management expectations
Average wastage
= 57977 / 31
Management expectations per day
= 1870
= 1200 copies
= 1870 – 1200
Wastage more than management expectations
= 670 copies
FOR NEWSLINE-45
Average wastage = Total No. of. Initial copy wastage
Total No. of Days in a month
Wastage more than management expectations = Daily wastage in average –
Management expectations
Average wastage
= 69784 / 31
Management expectations per day
= 2251
= 1200 copies
= 2251 – 1200
Wastage more than management expectations
69
= 1051 copies
Explanation:
1. Management expectations are an initial wastage of 1200 copies
2. CITYLINE-35 is printing 670 copies more than management
expectations per day
3. NEWSLINE-45 printing line is printing 1051 copies more than
management expectations per day
4. Analysis have to be done to bring down the initial wastage
5. In CITYLINE-35 machine, they print single edition
6. In NEWSLINE-45 printing line, they print two editions
4.6.4. START-UP WASTE ANASLYSIS FOR FEBRUARY 2015:
INITIAL WASTAGE
DATE
CITYLINE-35
NEWSLINE-45
01-02-2015
1816
4711
02-02-2015
1860
1661
03-02-2015
2740
2360
04-02-2015
1921
1668
05-02-2015
2214
1881
06-02-2015
2039
2362
07-02-2015
1202
2051
08-02-2015
1713
3312
09-02-2015
2554
1699
10-02-2015
2026
2540
11-02-2015
2314
1654
12-02-2015
2019
1990
13-02-2015
2165
2254
14-02-2015
2298
1631
70
15-02-2015
2936
3410
16-02-2015
1536
1763
17-02-2015
1891
2516
18-02-2015
1914
1878
19-02-2015
1678
1920
20-02-2015
1969
2615
21-02-2015
1982
1366
22-02-2015
1685
3472
23-02-2015
1596
1664
24-02-2015
2253
2515
25-02-2015
2098
1790
26-02-2015
2249
1823
27-02-2015
2123
2611
28-02-2015
2046
2108
TOTAL
56837
63225
Table 3. Initial waste analysis for February
71
Startup wastage analysis (City Line Express Feb 15)
3200
3000
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
wastage copies
management expectation
Graph 3. Initial waste analysis for city line express
Startup wastage analysis (News Line 45 Feb 15)
5000
4800
4600
4400
4200
4000
3800
3600
3400
3200
3000
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
wastage copies
management expectation
Graph 4. Initial waste analysis for news line 45
72
CALCULATIONS:
FOR CITYLINE-35
Average wastage = Total No. of. Initial copy wastage
Total No. of. Days in a month
Wastage more than management expectations = Daily wastage in average –
Management expectations
Average wastage
= 56837 / 28 = 2029
Management expectations per day
= 1200 copies
= 2029 – 1200
Wastage more than management expectations
= 829 copies
FOR NEWSLINE-45
Average wastage = Total No. of. Initial copy wastage
Total No.of. Days in a month
Wastage more than management expectations = Daily wastage in average –
Management expectations
Average wastage
= 63225 / 28
Management expectations per day
= 2258
= 1200 copies
= 2258 – 1200
Wastage more than management expectations
73
= 1058 copies
Explanation:
1. Management expectations are an initial wastage of 1200 copies
2. CITYLINE-35 is printing 829 copies more than management
expectations per day
3. NEWSLINE-45 printing line is printing 1058 copies more than
management expectations per day
4. Analysis have to be done to bring down the initial wastage
5. In CITYLINE-35 machine, they print single edition
6. In NEWSLINE-45 printing line, they print two editions
74
CHAPTER 5
FINDING AND FACTORS
5.1. Problems Found In Dinamalar Press
 Air tube burst
 Auto pasting copies
 Auto pasting failure
 Electrical fault
 Folder jam
 Ink overflow
 Paper roll up in roller
 Plate correction – News change
 Plate cut
 Plate registration out
 Plate scumming
 Power failure
 Reel shaft - air leakage
 Registration out
 Scum due to no water in water trays
 Scum on paper
 Water overflow or no flow of water
 Web break – joint reel
 Web break – reel problem
 Web break after pasting
75
5.2. MAJOR PROBLEMS
 Auto pasting failure
 Auto pasting copies
 Web break
 Web break – joint reel
 Folder jam
 Registration out
 Air tube burst
 Plate scumming
 Electrical fault
The expected reasons for more initial wastages are
 Part of the machine is with CIP3 ink control
 Part of the machine is with manual inking facility
 More than 50% Indian-made reels are used, which leads into
less paper tension control and registration problem and headmargin & side-margin control, due to loose winding and paper
strength
 Due to poor reel handling, (transport method)
 Printers & operators orientation training
Reason for web loosen
 Valve damage
 Not enough air inside the shaft
 Weak tube
 Puncture in tube
 Button over pressure
 Paper improper center
76
 Worn out brake pad
 Worn out disc
 Improper auxiliary air control
 Dancing roller pressure
 Improper blanket under packing
 Improper paper pulling
5.2.1. Web break
LOCATION/SYMPTOM
REASON
REMEDY
Before printing unit
Improper adjustment of
Adjust tension control
tension control roller
roller in the reel stand
and/or in the infeed unit
Knife is activated by the
Check setting of web
web break detector
break detector, the
sidelay register and the
web for “baggy” parts.
In or after the printing unit
Imperfect start-up
Check start-up sequence
sequence
Too tacky ink
Make sure that press and
pressroom have a
temperature of about
20°C
Water in cylinder gap
Reduce water feed and
clean gap with
compressed air
77
Cleaning agent in the
Clean more thoroughly,
cylinder gap
use tape to cover the gap
during cleaning
5.2.2. Auto pasting failure, Auto Pasting Copies
LOCATION/SYMPTOM
REASON
REMEDY
Start of the web fails to loosen
No glue on the reel
Apply glue according to
from the new reel in the reel
instruction
stand
Applied glue has dried
Renew glue; check glue
out
properties; don’t apply
glue too early and make
sure that no dust sticks
on the glued part
Perforated tabs are too
Use perforated tabs
strong, or glued in the
which are recommended
wrong position
and glue them according
to instructions
Splicing arm does not
Check pneumatic,
work, or is incorrectly
mechanical and electrical
adjusted
functions, and distance
between splicing arm
and reel
78
Start of the web loosens either
Reflective tab in wrong
Prepare reel according to
too early or too late
position
instructions
Function of splicing arm
Synchronize
is not synchronized with
mechanically,
the start of the web
pneumatically and
electrically; check the
speed of the reel stub
Start of the web loosens in
New reel rotates too
Check, and - if necessary
time, but old web breaks
slowly or too quickly
synchronize; tighten the
immediately
belts
Wrap in the press before the
Top of the splice has
Improve the reel make
unit
turned over
ready procedure, check
whether the startautomatic(with running
belts) start too quickly
Wrap within or behind the
Glue was squeezed out
Apply glue as thinly as
printing unit
(too much glue) and
possible and
sticks on cylinders or
appropriately; avoid
pipe rollers
gluing up to too close to
edges
Splice fails
Sensor is dirty or
defective
79
Clean or replace sensor
Knife cuts too early or
Check sequence of
too late or fails
splicing procedure
Dirty or worn-out paster
Clean, adjust or replaces
brushes or paster rollers
paster brushes or paster
rollers
Incorrect load on brake
Adjust according
instructions
Web break occurs somewhere
Wandering web
Adjust web tension;
in the press without evident
check chocking rollers
reason
and reel condition
thoroughly
Reel is not centered
Bring web in sidelay
register
Telescopic reel
Adjust side lay register
continuously
Transport damage or
Remove some layers
crack at the web edge
from the reel or out the
damaged part
Too high a winding
Strip layer with too high
tension in outer layers;
tension; if it happens in a
80
sheet is stretched beyond series of reels contact
its elastic limit or even
newsprint suppliers
cracked
Paste in slitter area
Avoid paste in slitter
area
5.2.3. Folder Jam
LOCATION/SYMPTOM
REASON
REMEDY
Web break before draw roller
Angle of turner bar is
Adjust setting of turner
not correct
bars
Excessive web tension
If possible, reduce of
feed of draw rollers or
the pressure of the
trolleys
Foreign matter
Clean rollers
accumulation on rollers
Web break at formers
Former angle is incorrect Adjust former angle
according to instructions
Former nose is worn out
Replace former nose
Incorrect setting of
Adjust the setting
nipping rollers
according to pagination
underneath the former
Excessive air
81
Reduce air pressure
5.2.4. Air tube burst
Reasons for air tube burst
 Valve damage
 Not enough air inside the shaft
 Weak tube (hardness - 60 shore )
 Puncture in tube
 Button over pressure
5.2.5. Registration out
FAULT
REASON
REMEDY
Circumferential and/or
Print image mounted not
Check mounting, replace
lateral register does not
correctly
printing plate
Circumferential and/or
Paper reel wobbling too
Change paper reel or
lateral register with
heavy
reduce printing speed
Paper web tension too
Check function of reel
low
brake, increase pressure
suffice
fluctuations
for dancer roller if
required
Paper reel loose on
Retention paper reel or
pneumatic shaft
replace pneumatic shaft
Printing plate defective
Replace printing plate
Defective
compensator roller
82
Check and reset
5.2.6. Plate Scumming
 Dampening water supply
Scumming over the entire print width
reducing
 Ink supply reducing
 Check dampening water cooling,
correct if necessary
 Check PH of dampening
solution, correct if necessary
(4.8 – 5.3)
 Check dampening rollers and
adjust them
 Minimize printing press force
(acc.to press manual)
 Ink supply to required places
Scumming in streaks over the print
direction
reducing
 Check dampening roller and
adjust if necessary
 Check dampening roller and
Different scumming over the print
width
adjust it
 Adjusting inking and damping
roller, replace roller bearings if
necessary
Other Reasons
 Unplanned retro fitting.
 Old punching and bending machine.
 Auto pasting failure
83
CHAPTER 6
SUGGESTION AND CONCLUSION
 Look for defect in printing like dot gain, slur trapping register errors etc.
For every symptom, analyze all possible contributory factors by the press.
Check, ascertain, attend and correct the defect.
 Look for defect in web running like loose web, web break, and margin
and register shift etc. for every symptom analyses and correct the defect.
 Closely monitor and look for abnormal sound, heat, vibration and
machine load, all through the production run. Parameters indicate
probable defects like lack of lubrication; wear unbalanced alignment
related problems. Analyses and attend.
 In all the three situations given situations given above. Do a deep study.
Any wrong diagnosis will lead to waste of time, man hours and may lead
to further complications.
 Do not attend to eliminate symptoms, but handle the root causes.
 While disassembling and re-assembling, apply the mind, do not perform
the act mechanically.
 Keep relevant drawing always for reference.
 Try to understand the functional aspects of each and every machines
element and their locations and positioning relevance.
 Go through the daily weekly and monthly maintenance schedules as
recommended by the manufacturers.
 The replacement parts and other consumable will be best if bought from
the manufacturers themselves. Any temptations for saving by going for
cheaper items will prove to be costly in a long run. Be pro-active and not
re-active. Engage the press crew for the basics maintenance and not a
separate team.
84
7. REFERENCES
1. Best practice TOOL BOX Web Offset by Champion Group.
2. Printing Machinery Maintenance by AGPC, Sivakasi.
3. Wastage Reduction and OEE in Newspaper Printing by Jacob jeba
reuben, Kumaresan, Palanikumar, Vikram.