Reach trusts in EAE's retrofit expertise to modernise computer systems on web press line

Print Solutions

Reach plc (until May 2018 Trinity Mirror plc), produces more than 240 local and regional newspapers, and also publishes the national Daily Mirror, Sunday Mirror, Daily Express, Sunday Express and Daily Star as well as sundry other newspapers and magazines with a nationwide circulation.

Its subsidiary, Reach Printing Services Ltd, is responsible for producing the newspaper print editions. In addition to the group's own titles, it also contract prints a variety of newspapers and magazines on behalf of other publishers. The two largest sites are located in Oldham and Watford, though the company also has facilities in Birmingham, Cardonald (Scotland), Luton and Teesside. Out of these six sites, the printing centre in Oldham outputs the highest page volume. Between six and seven million newspapers and magazines leave the premises every week. Reach Group products account for around 55% of the site's total print volume ­– the remainder are external contracts like The Guardian, Daily Mail, Mail on Sunday and The i, plus many other titles. Production takes place on seven days a week at night and four days a week in the daytime. The print shop in Oldham works with a Wifag evolution 371 web press line, which was commissioned in 2006 and originally comprised four sections, but was expanded by an additional section in 2008 and again in 2009. The line has 19 four high towers overall as well as six jaw folders and 19 reel stands. It has been operated and controlled from the outset using press control and control console technology from EAE Engineering Automation Electronics and is equipped with eight EAE Baltic Star control consoles. For many years now, the relationship between Reach Printing Services and EAE has been marked by a constructive partnership. The printer first signed a service level agreement with EAE back in 2011.

The need to modernise the computer systems of the control consoles and the section controls in order to maintain production reliability was recognised some time ago. Compared to the heavy mechanical components of newspaper web presses, computer hardware and PCs tend to have a relatively short lifecycle. Malfunctions and breakdowns typically occur more frequently towards the end of the service life, with direct implications for press availability. ‘We have started experiencing equipment failures and the risk of impairments to our production was rising steadily,’ reported Alan Marsden, IT systems manager at Reach Printing Systems (Oldham) Ltd. ‘In our experience, spare parts for our computers were getting harder and harder to come by. On top of that, support for the operating systems we use has been withdrawn.’ After careful deliberation of the options, the Reach managers decided in favour of a complete retrofit of all PCs belonging to the EAE systems on the web press. They did this with the aim of increasing system reliability and availability and extending the life of the equipment as a whole. ‘We expect a retrofit specialist to provide us with a turnkey solution at a reasonable cost and to implement it without disrupting or interrupting our production workflows any more than absolutely necessary,’ Alan explained. EAE was an obvious choice here in view of its extensive experience and successes in the retrofit business.

The order for EAE involves replacing the existing PCs in the EAE system environment with eight new control console PCs,12 section control PCs, six PCs for the EAE Info reporting and logging system, two EAE Info Remote Workstations and one EAE Service PC. Four replacement units of the various PC models round off the hardware package. On the software side, the printer will be supplied with an update to the latest version of the EAE Info System plus the newest versions of both the operating systems, namely RMOS (an OS for industrial environments) and Windows.

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