Globe tar­get­ing Fe­bru­ary ’17 go-live in Taun­ton

Newspapers & Technology Magazine - - Front Page - BY TARA MCMEEKIN CON­TRIBUT­ING WRITER

The Bos­ton Globe is mov­ing full speed ahead at its newly minted 328,000-square-foot pro­duc­tion fa­cil­ity in Taun­ton.

The fa­cil­ity will pro­duce The Globe and other pa­pers it pub­lishes, as well as its com­mer­cial con­tracts with The New York Times, the Bos­ton Her­ald, the Worces­ter Tele­gram & Gazette, and its new­est client, Gannett flag­ship USA To­day, which went into pro­duc­tion at the ex­ist­ing fa­cil­ity on Jan. 25. The Globe ex­pects to pro­duce the first prod­ucts at the new plant some­time around April 4, ac­cord­ing to Vice Pres­i­dent of Op­er­a­tions Rich Ma­sotta, al­though not all presses and pro­duc­tion ca­pac­ity will be live un­til Fe­bru­ary 2017.

The Globe first an­nounced that it had found a new fa­cil­ity in May 2015 (see News & Tech July 2015). The build­ing — for­merly owned by Cham­bers Prop­er­ties — seems to be a per­fect fit for a buzzing news­pa­per pro­duc­tion op­er­a­tion.

“We found the ware­house in Taun­ton and it was con­ducive to ex­actly what we wanted to do,” Ma­sotta told N&T.

The big­gest boon, he said, will be get­ting into a fa­cil­ity where ev­ery­thing can live on one level vs. the three lev­els at The Globe’s ex­ist­ing 700,000square-foot pro­duc­tion site.

The new fa­cil­ity, lo­cated at 330 Con­sti­tu­tion Drive, has been va­cant since 2011 when its last ten­ant, the Bos­ton Ap­parel Group, va­cated.

Some 282,000 square feet of the fa­cil­ity will be ded­i­cated to pro­duc­tion and dis­tri­bu­tion op­er­a­tions, with of­fices com­pris­ing the re­main­ing 46,000 square feet.

In Fe­bru­ary, The Globe tapped Pressline Ser­vices for its FlexPress in­fra­struc­ture, which will equip the fa­cil­ity with 22 zones and four fold­ers, and po­si­tion the pub­lisher to court ad­di­tional com­mer­cial work. Press in­stal­la­tions be­gan in early De­cem­ber. “In to­tal, Pressline is retrofitting 140 Goss Ur­ban­ite units with all new con­trols and ink­ing sys­tems,” Ma­sotta said.

The press in­fra­struc­ture pro­vides three pages across and right an­gling into a dou­blewide folder, giv­ing The Globe near dou­ble width per­for­mance, Ma­sotta said.

The FlexPress will fea­ture EAE Press Con­trols, Rexroth shaft­less tech­nol­ogy, Per­retta motorized foun­tains, Tech­no­trans damp­en­ers, WPC reg­is­tra­tion con­trols and NELA lock­ups.

“We also have a four-tower Ten­sor press, and we plan on mov­ing that over, along with a UV cur­ing sys­tem,” Ma­sotta said. “We will have four zones that will be able to print all com­mer­cial work and USAT. We will have the press ca­pac­ity to print jack­ets and we will have a sig­nif­i­cant amount of day­side ca­pac­ity — so we’ll be bring­ing a lot more com­mer­cial work in.”

Three-up, chem-free CTP

On the pre­press side, The Globe se­lected CTP equip­ment from Agfa to feed the presses. The pub­lisher is in­stalling four Ad­van­tage N-TR high-speed plate­set­ters with N94 vi­o­let, chem­istry-free plates and four At­tiro high-speed clean-out units. The pub­lisher is also in­stalling four Nela VCP 1200 au­to­matic vi­sion reg­is­ter punch ben­ders.

“We are hop­ing to have our platemak­ing equip­ment in­stalled by the end of Jan­uary, and be­gin test­ing in early Fe­bru­ary,” said Ce­sar Molina, di­rec­tor of New Eng­land Me­dia Group Pre­press Op­er­a­tions. “We’re switch­ing to 36-inch plates for 3-up, or three pages per plate.”

The 3-up process would have slowed down the work­flow with the ex­ist­ing equip­ment, prompt­ing the pub­lisher’s move to the high-speed CTP equip­ment,” Molina added.

The Globe’s re­la­tion­ship with Agfa, which is lo­cated just 30 min­utes away in Wilm­ing­ton, dates back 13 years.

“Our front-end sys­tem is also Agfa, giv­ing us con­sis­tency,” Molina said. “Per­for­mance has been great and we haven’t ex­pe­ri­enced any sig­nif­i­cant is­sues with plates af­fect­ing the press­room over the years.”

Build­ing a press­room

While the fa­cil­ity is by all ac­counts per­fect for a news­pa­per and com­mer­cial print­ing op­er­a­tion, Ma­sotta said a pro­ject of this mag­ni­tude is never with­out it’s ob­sta­cles.

“Build­ing a press­room from scratch is a chal­lenge with all of the con­struc­tion and com­po­nents,” he said.

The Globe part­nered with The Austin Co. on the de­sign and lay­out of the new fa­cil­ity. Austin got in­volved in the pro­ject in Oc­to­ber 2014 and brought to the ta­ble an in­te­grated team of ar­chi­tects, en­gi­neers, and pro­ject man­agers.

“Be­cause it’s not a man­u­fac­tur­ing or pro­duc­tion space, me­chan­i­cal, elec­tri­cal and plumb­ing sys­tems have to be brought up to speed to ac­com­mo­date a man­u­fac­tur­ing fa­cil­ity,” Mike Pu­sich, man­ager of fa­cil­i­ties de­vel­op­ment for Austin Co., told N&T. “We looked at struc­tural, me­chan­i­cal, elec­tri­cal, plumb­ing, fire pro­tec­tion and ar­chi­tec­tural aspects, and mod­i­fied the mas­ter plan to fit.”

Turner Co. han­dled con­struc­tion on the build­ing.

“They liked our in­te­grated team and our news­pa­per ex­pe­ri­ence,” Pu­sich said.

Pu­sich said very lit­tle demo work was re­quired on the fa­cil­ity.

“In terms of ba­sic bones, The Globe did a re­ally good job of se­lect­ing a fa­cil­ity that was a good fit for a news­pa­per,” he said.

The Globe will be able to use most of the ex­ist­ing of­fice space and the cafe­te­ria with no mod­i­fi­ca­tions. One kitchen area has been mod­i­fied and re­designed to serve as locker rooms.

“If you were to start with a blank piece of pa­per, this was a great fit,” Pu­sich said.

The ex­ist­ing ware­house did re­quire the re­moval of col­umns to ac­com­mo­date presses and the ad­di­tion of slabs to en­sure they could han­dle the press loads.

“There weren’t many sur­prises and it was largely what you’d ex­pect turn­ing a dis­tri­bu­tion cen­ter into a news­pa­per pro­duc­tion fa­cil­ity,” Pu­sich said

The Globe and Austin Co. opted for air ro­ta­tion units in the fa­cil­ity for air han­dling in the plant.

“We couldn’t hang duct­work be­cause we had to use what ca­pac­ity we had for con­veyor and ink pip­ing loads,” Pu­sich said. “Air ro­ta­tion al­lowed us to put units on each side of the build­ing. They blow to the cen­ter of the build­ing, and that was the ideal so­lu­tion for this fa­cil­ity.”

Plumb­ing, elec­tri­cal, and me­chan­i­cal work to sup­port the press in­stal­la­tion has been ex­ten­sive. Austin part­nered with Tech- no­trans for the ink pumps and pip­ing, and Pressline to ac­com­mo­date plumb­ing as­so­ci­ated with the re­con­di­tioned presslines.

“The press con­cept was re­ally well de­vel­oped — Pressline did a good job of tak­ing the prod­uct mix and con­fig­ur­ing Ur­ban­ite presses to han­dle that full range of prod­ucts in a very ef­fi­cient way,” Pu­sich said. “It gives The Globe a tremen­dous amount of flex­i­bil­ity.”

Pu­sich ap­plauds the time The Globe has de­voted to the move, as­so­ci­ated in­stal­la­tions, and go-live.

“They’ve done an ex­cel­lent job of putting the job to­gether — the team and the sched­ule — they’re not rush­ing it and they’ve left a good amount of time for com­mis­sion­ing the presses, train­ing and bring­ing the presses on­line in a phased man­ner.”

Ma­sotta at­tributes the suc­cess of the pro­ject to Globe owner John Henry’s com­mit­ment to the pa­per.

“It’s a big in­vest­ment by John Henry,” Ma­sotta said. “And there is no one else that’s re­ally do­ing that kind of in­vest­ing in news­pa­pers — it’s a huge ges­ture.”

The ex­te­rior of The Globe’s new 328,000 square foot pro­duc­tion fa­cil­ity in Taun­ton. The pub­lisher hopes to take pro­duc­tion of all in­ter­nal and com­mer­cially pro­duced prod­ucts live by Fe­bru­ary 2017.

Photo: The Austin Co.

Pressline is han­dling the press in­stal­la­tion at the new fa­cil­ity and through its FlexPress in­fra­struc­ture is retro tting 140 Goss Ur­ban­ite units.

Newspapers in English

Newspapers from USA

© PressReader. All rights reserved.