Eyebrows in the middle of foreheads. Lips located near eyes. While this may sound like a scene out of a horror movie, it proved to be a real problem for one Midwestern newspaper. The Journal Times, a Racine, Wisconsin-based daily, had a noticeable registration problem that created more than just a few interesting photographs. The problem also led to a number of customer complaints. So many, in fact, that Publisher Peter Selkowe and Pressroom Supervisor Carl Simon decided that they needed a solution, and quickly. Adding to the urgency was the Journal Times' own efforts to publicize its new KBA Motter Colormax flexographic press. Since the Journal Times had highly touted its move into flexo in 1995, readers felt they were getting bad service, especially after all of the publicity surrounding the move to more color. “It's frustrating to have your readers complain about something and you know they're right,” says Peter. “It hurts.”

Dedicated to Quality Registration problems, especially at a newspaper such as the Journal Times, are unacceptable. For one thing, many of the paper's readers understand printing. Racine is home to Golden Books, a publisher of children's books. Additionally, readers are used to the quality of heatset and magazine work and expect the same of their newspaper. And due to its size, (36,000 weekly and 38,000 Sunday circulation) the Journal Times had to live up to the expectations of its community. Peter noted, “Newspapers have a close, personal relationship with customers.” With its 143-year history, the Journal Times is deeply committed to that relationship.

Poor registration also hampered the newspaper's tight schedule. A one-shift press crew of five to six people work to put out the paper in a short time frame. Each night, the Journal Times runs two editions, using two to three units of the press. The first edition is out the door by 1:30 a.m. for county distribution. The press is then replated and the metro edition (city and suburbs) runs. This edition is out the door by 4:00 a.m. Typical run sizes range from 5,000 to 35,000 copies. When things go wrong on press, the disruption can severely affect delivery times.

Just as importantly, the registration problem was costing the newspaper money. During a three-day trial period, the press crew pulled and set aside every bad copy. The resulting waste figures ranged from 12 to 13 percent. If allowed to continue, these numbers would consume the paper budget. “Either the newspaper was going to throw out thousands of papers each night or invest in a solution,” Peter notes.

The registration errors began soon after the new press was installed. The problem occurred whenever a paper roll needed to be replaced. Having no autopasters, the press had to stop in order to change the paper roll. With every roll change, the press would fall one-eighth of an inch out of register, primarily when decelerating.

In attempting to find a solution, the Journal Times first contacted the press manufacturer. After numerous attempts to repair the problem, the newspaper continued to fall out of registration. Installing autopasters would have eliminated the problem, but that solution was not an option. Finally, the Journal Times decided to investigate electronic registration systems. After calling in numerous vendors, Carl elected to work with QuadTech, whom he found to be the most responsive.

Unique Solution Corrects the Problem

QuadTech proposed its Print-to-Process Controller 3000X as a potential solution. This innovative technology automatically controls unit-to-unit registration in either mark or pattern mode. It's the system's second application that the newspaper decided to pursue. The 90-day guarantee on the system also played a part in the Journal Times' decision. If the Print-to-Process Controller failed to correct the registration problem, only the original installation cost would be incurred by the newspaper. “QuadTech was more than willing to stand behind their system,” comments Carl.

The Journal Times' pressroom is unique. When installed, its Colormax press was slipped into the spot vacated by the newspaper's old letterpress units. The press consists of two stacked units, a mono on the bottom and a common impression cylinder on the top. QuadTech installed the Print-to-Process Controller's encoder on the press line shaft. Originally, the black seemed to be moving away from the colors. In actuality, however, the colors were moving away from the black. When the press slowed down to make a roll change, the actual printing units would move, causing the color to fall out of register. Therefore, the Print-to-Process Controller 3000X couldn't keep register with the encoder installed in its original line shaft position. QuadTech then engineered a unique way to track the cylinder position, which solved this problem. The result? The color never moved. Initially, the Journal Times only configured one print unit this way. Afterward, the newspaper decided to configure a second print unit as well.

Immediate Results

When compared to an autopaster, the Print-to-Process Controller 3000X was a relatively inexpensive solution to the problem. “They (QuadTech) took an off-the-shelf system and modified it to what we wanted it to do,” Carl notes. The results have been dramatic. Previously 250 to 300 newspapers were thrown away on every stop, depending on the press speed. With the Print-to-Process Controller 3000X installed, the newspaper tosses about 40 newspapers per stop. Waste figures now average between 1.8 and 2 percent each month. More importantly, the newspaper has salable copies within five revolutions. “It's worked flawlessly,” Carl adds. The Journal Times finds the Print-to-Process Controller 3000X easy to use. “The press crew picked up the system very quickly,” he adds. Since the gutters of the newspaper are too small for marks, the system runs strictly in pattern mode. The system's easily adjusted scanner bar accommodates a variety of web widths, something the newspaper finds helpful. As for his experience with QuadTech, Carl comments, “I had good luck getting the answers I needed, when I needed them.” The QuadTech service and engineering teams also impressed Carl. “They knew what they were doing,” he says.

Peter echoes Carl's thoughts. “We had a good relationship from the start. QuadTech is a printing company and understands what we do.”

Working together, the Journal Times and QuadTech turned a frustrating situation into a positive one for both. “We looked at it as a win-win situation for all of us,” Carl explains. As for irate customers, Carl has not been contacted by a single one. He notes, “We haven't heard a word, which tells us something. The calls just stopped.”

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