The two Ferag systems (supplied by Kamboo Marketing), each with eight hoppers, run at speeds of up to 45 000 copies/hour, more than doubling the previous capacity for the company’s manroland Geoman press.
One challenge was to allow the business to continue as usual despite extensive building operations during the project’s implementation. ‘We installed a temporary offline Ferag Easysert system to keep work flowing while the new lines were being put in place,’ Conrad explains. ‘The old ETR system is also to be retained as an offline system to provide backup should any lines go down,’ he adds.
The prepress department has also been powered up with the installation of an additional Krause LS Jet CtP line. This brings the total lines to three, each producing 720 plates/hour. ‘As a result, the Cape Town plant can now handle higher volumes faster and more efficiently than before,’ Conrad reports.
From a health and safety perspective, building enhancements include better lighting, improved ventilation and emergency exists, and the replacement of ceiling boards by more appropriate material.
But Paarl Coldset Paarden Island isn’t the only plant to receive a makeover. The Port Elizabeth operation is being expanded and upgraded at a cost of R15-million. This includes the installation of sound walls to minimise the environmental impact on the surrounding area, and the installation of a manroland Cromoman 45, originally from the Paarl Post plant.
In addition, an SLS 300 insert line from Müller Martini, with six hoppers, has been installed.
Paarl Media’s proposed acquisition of the Natal Witness printing plant, to be rebranded Paarl Coldset Durban (pending Competition Tribunal approval), will ensure that customers in KZN also enjoy a cost-effective, quick turnaround service on their doorstep. Plans are also in place to upgrade this facility to streamline workflow and enhance capacity through investment in additional presses and mailroom systems.
‘Nationally, we’re bringing the Paarl Coldset operation into the 21st century,’ concludes Conrad Rademeyer. ‘This will give our customers the most modern and efficient coldset facilities in the country, which translates to cost-efficient, reliable and quick printing of their products.’