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WASTEMASTER WASTE CONTROL SOLUTION CUTS RAW MATERIAL
COSTS
WasteMaster is a waste control system that offers printers
and converters the possibility of monitoring and controlling
waste generation throughout the manufacturing process.
The system is designed to handle both sheet and web fed
machines with or without in-line finishing and is a series
of software modules contributing information that facilitates
tracking and monitoring of waste from make-ready to finished
product.
WasteMaster accurately identifies and records where
waste is occurring on the production line and also provides
information on the performance of consumables from different
manufacturers with comparable and qualified data that
indicates the consumption and efficiency of each product
per job, per press.
Unqualified waste factors can be in the 10 to 20% range
of raw materials. In order for printers and converters
to effectively reduce waste levels, they have to be able
to accurately determine the amount of waste generated
on-line and understand the point at where various waste
generators are located. Comparisons have to be made at
a variety of locations: at the reel stand, during reel
changes, during make ready, during the printing and converting
stages and at the delivery end. In evaluating the impact
of waste on every facet of the printing operation, from
raw materials right through to waste disposal, a reduction
in waste levels from 15 to 13.5% (10%), for example,
can have a significant impact on the bottom line.
WasteMaster records data for incoming reels or pallets
that are weighed validated and identified in the goods
inwards area. The labels generated are used as identification
for pallet and reel tracking and electronic physical
stock checks including barcode shooting on the Shop floor
data capture station located on the press in-feed section.
The weight, width, gsm, microns, supplier, order number,
reel batch as it is presented to the machine is also
identified.
A series of non-invasive electronic sensors sited on
the printing press or production line relay back to the
control system the status of the machine: speed, the
type of substrate being processed, copy count and meterage.
Waste is broken down according to type and operation,
e.g. Slab and core from reel fed machines is recorded
via a weighbridge, make ready and running waste for various
operations is measured by the sensors. Both operate in
real time `on-line'. The sensors are non-invasive in
that there is no need to drill holes in or alter machinery
in any way thus allowing all types and ages of presses
to be attached including folding and finishing equipment.
In operation reels are weighed on entry to the factory
or by electronic manifest from the supplier booking them
directly into stock & updating purchasing. Bar Coded
reel labels are 'swiped' at the reel stand, booking
the reel out of stock and onto the waste control system.
Slab and core waste is deposited into a container positioned
on the reel stand weighbridge. Post press waste is deposited
into containers on printed waste weighbridges or may
be remotely weighed. Waste, good copy, press speed and
operation are fed back to the control system where a
full report analysing press performance and waste data
can be accessed. It is not necessary to have extra weighbridges
to monitor production waste as this is recorded via the
electronic sensors.
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