Magazine article Editor & Publisher

Beveled-End Cores in Baltimore

Magazine article Editor & Publisher

Beveled-End Cores in Baltimore

Article excerpt

WITH WEB BREAKS during unwinding resulting in average downtime of half an hour, newspaper printers view them as a major concern, especially when printing two daily editions.

With a tiny window for printing, 30 minutes can mean the difference between out on time and out of luck.

Printing more than 2 million copies per week, the Baltimore Sun was seeing substantial cost increases owing to out-of-round rolls, web breaks and downtime during its transition to a new plant with new presses running larger-diameter rolls. To improve efficiency, the Sun asked for help from its newsprint suppliers, including Garden State Paper Co., Elmwood Park, N.J.

Garden State determined that the problems were not caused by manufacturing errors, but by the need for an upgraded core able to support the weight of the larger rolls. Garden State's mill, in turn, sought a solution from its core supplier of 15 years, Sonoco Products Co., Hartsville, S.C.

Sonoco's answer was the CPC-B, a new beveled-end, non-returnable core that enhances winding at the mill and runnability in the pressroom. The beveled end assures a secure fit in the reel stand, eliminates metal ends and still protects the the core from damage.

"We were skeptical about converting to a non-returnable core," said Glenn Davis, the Sun's newsprint supervisor. "But, with our short lead times, and with every break translating into lost sales on the street, we needed to do something to rectify the situation immediately."

Founded 33 years ago by newspaper publisher Richard B. Scudder, Garden State was the first mill to make newsprint solely from recycled paper.

Similarly, its own supplier, Sonoco, annually recycles more than 1 1/2 million tons and is among the world's largest consumers and processors of recovered paper. Sonoco has been recycling and making products from recovered materials since the 1920s. Today, more than 70% of the its products incorporate recycled material; many are made from 100% recycled material.

Though not reusable as a core, the non-returnable CPC-B is recyclable.

"Sonoco's recycling history is very important to us, and to our customers," said Steve Melton, finishing and shipping supervisor at Garden State. "Not only do they provide us with the most technologically advanced products as soon as they become available, but we know they are also serious about protecting the environment."

The companies cite another reason for their long relationship (Sonoco has been the mill's only core supplier for the last 12 years): A dedication to service demonstrated by their response to the Sun's problems.

Between January 1992 and July 1993, the Sun moved all printing from its Calvert Street building to the new Sun Park plant, where Goss CT-50 reel-stands on the four Colorliner presses hold larger, 50[inches] newsprint rolls.

Before converting to the CPC-B core, the pressroom was using an unslotted core with metal ends on the new presses, with very disappointing results. Some problems inherent to using cores with metal ends are possible operator injury caused by handling jagged metal, extra costs and labor time required to cap the cores, risk of core damage if the paper is unwound too close to the core, and start-up difficulties if the metal ends are not aligned properly.

Despite these drawbacks, metal ends protect core integrity from the following problems during unwinding:

* Misalignment, when inside core plies have been folded over and pushed inside, setting the roll off center and creating a lopping and roll bounce, can lead to web breaks. A core that is misaligned and off center won't run and will have to be removed. …

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