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

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