K-R Tips on Reducing Waste
A white paper titled "Knight-Ridder Newsprint Waste-Reduction Ideas and
Initiatives" was distributed at the latest America East conference. Some of
its best ideas are listed below.
Page/Paper Layout/Scheduling:
- Standardize the configuration of the paper, where possible, to reduce
setup time between edition days.
- Where possible, limit zoned products to the same page count and same spot
colors to reduce setup waste.
- Improve scheduling of similar products to run on the same day.
- Combine editions where possible to reduce the number of press starts.
- Look at running more products "collect" to cut waste in half.
- Limit process color to two sections daily.
- Reduce color usage, especially on inside pages.
- Run half-sheet (gatefold) rolls to increase page counts in single-page
increments only and reduce number of house ads.
Newsprint Handling:
- Switch to lower basis-weight newsprint.
- Reduce newsprint web widths.
- Increase newsprint inventories before each price increase. Rent additional
storage space to handle the overflow.
- Be vigilant in checking railcars and trucks for damaged newsprint and
filing claims.
- Conduct retraining for unloading of trucks and stripping of newsprint.
- Reduce number of sheets of newsprint removed when roll wrapper is removed.
- Reduce number of sheets removed when paster patterns are made up.
- Prevent excessively damaged or wet rolls from reaching the pressroom.
- Deliver rolls to the pressroom with the body wrapper intact to reduce
damage. Do not remove until loading in the reel.
- Report problems caused by imperfect rolls immediately to the manufacturer,
asking for appropriate credit.
- Use a computerized roll-distribution system that allows the use of certain
vendors' paper in certain units.
Reels:
- Set paster core cutoff at lowest point.
- Perform paster-panel routine maintenance on a more frequent basis.
- Initiate a top-notch preventative-maintenance program for press reels.
- Periodically check tape for proper adhesive qualities, strength, etc., to
avoid missed pasters.
Maintenance/Setup/Equipment:
- Increase focus on properly inking and purging the ink train.
- Check press setup for accuracy before startup.
- Verify all press compensator settings and web paths prior to press start.
- Improve maintenance and cleaning.
- Complete a page-pack rebuilding program to reduce the amount of ink on the
sheets when walking the press during make-ready times.
- Add a press PAR/PCS system to press to get to salable copies more quickly.
- Use a plate verifier to ensure color plate registration and reduce stops.
- Use a pin-register plate lockup system on press to ensure plates are
positioned in proper registration.
- Monitor paster misses and web breaks.
Press Run
- Use an "autocomp" registration system on press to maintain
circumferential registration integrity.
- Reduce or eliminate the number of papers pulled to catch a paster pattern.
- Run closer to the draw.
- Reduce the number of overruns on special sections.
- Keep "checking" papers for end-of-run shortages and other uses.
- Reduce number of papers used and discarded by personnel during the run.
Training/Other:
- Keep an open dialogue on press-waste control and reward good
performance.
- Implement a waste-reduction incentive program for all people who directly
influence newspaper waste.
- Review and police "good copy" definition.
- Work with the press crew to produce salable copies faster.
- Do more press training for ink/water balance.
Mailroom/Circulation Distribution:
- Reduce pre-run overrun percentage built into the press order.
- Reduce zone wrappers to a single sheet.
- Maintain conveyer systems so that papers are not dropped (and spoiled).
- Maintain and fix totalizer-system problems to ensure accurate counts.
- Improve maintenance on conveyer counters/sensors.
- Improve stacker maintenance to ensure accurate counts and reduce spoils.
- Improve inserter maintenance to ensure accurate counts and reduce spoils.
- Use automated counting equipment to ensure more accurate counts.
- Place racks for TMC products in apartment complexes rather than mailing
products to each unit.
Returns:
- Track number of returns by box and by carrier route.
- Encourage more recovery runs to reduce returns from single-copy carriers.
- Reduce service copies to a minimum.
In-House Copies:
- Use returns for accounting (tearsheets), the library (morgue), the
newsroom, in-house copies.
- Use early copies for in-house uses.
- Periodically audit office copies for possible reductions, especially
bundles that are never opened.
Recycling:
- Set up drop boxes for newspapers in areas where recycling isn't
available.
- Recycle all press spoils, circulation returns, office copies and anything
else on newsprint.
- Recycle office white waste.
- Recycle Kraft-wrap newsprint roll protectors and headers.
TechNews Volume 2, Number 3: May/June 1996
©1997 Newspaper Association of America. All rights reserved.