Magazine article Editor & Publisher

E&P Technical: Taking the Wraps off PowerWrap

Magazine article Editor & Publisher

E&P Technical: Taking the Wraps off PowerWrap

Article excerpt

Four years after introducing a concept machine, GMA demonstrated its PowerWrap for containing and protecting sections or entire editions with inserted or collated preprints.

Unveiled in June at the formal opening of the company's new headquarters in Allentown, Pa., PowerWrap moved from prototype to product on schedule two months later. Gannett's Journal and Courier in Lafayette, Ind., is its first U.S. buyer.

Part of a larger post-press contract signed last month, PowerWrap was selected to contain inserts and onserts in a package formed by the smaller Berliner format to which the paper will convert next fall (E&P Online, March 21, 2005).

PowerWrap met concerns posed by Journal and Courier President and Publisher Gary Suisman: Automatically repairing missed inserts when the Berliner jacket is shorter than the inserts; delivering a package to tie lines without having inserts fall out; not tearing inserts that are larger than the Berliner jacket when a bundle is tied; and ensuring that inserts are not lost or removed at single-copy sales locations.

Consolidating work at four locations, GMA's 200,000-square-foot building encloses well over twice the floor space of its old main plant -- a former Capitol Records warehouse, according to mechanical engineering manager Tim Voorhees. Before occupying their new workplace in fall of 2004, some of the 350 employees working two shifts had begun a consulting group's "Lean 6" training in Six-Sigma methodologies, with the aim of improving processes throughout -- reducing time, space used, and variability, while increasing productivity and consistency in quality.

The original aims for PowerWrap were to reduce space and staff needs while assuring secure in-plant assembly of freestanding insert packages or Sunday completes. The plastic packaging contains not only the large numbers but also the irregular sizes and bulky shapes of everything from single-sheet ads to product samples. …

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