In recent years, the impact of the digital revolution on the printing industry has been both positive and profound. In particular, computer-to-plate technology has let publishers eliminate one of the most time-consuming steps in the printing process: plate film production. To take advantage of this breakthrough, and therefore give its customers fast and cost-effective service, Banta Corp. has invested in the latest scanning and image processing equipment, while also increasing its digital storage capacity.

Banta operates more than 40 facilities globally. It offers publishers of education and general books, special interest magazines, consumer and business catalogs, a complete range of printing and digital imaging services. Banta’s printing business includes web, sheet-fed, and digital printing capabilities, as well as complete binding, coating, and cover options.

To offer quality print services while keeping pace with rapidly changing print technology and its customers’ increasingly shortened cycle times, Banta must ensure that its largest capital investment—a lithographic offset printing press—operates productively. Printing presses have a life cycle of up to 20 years, and many are remanufactured in-house to keep up with technological innovations and process improvements.

Specifically, the power control components that manage the presses—contactors, starters, motor control centers, and disconnect switches—must reliable and easily accommodate field modifications and upgrades. Additionally, the dc drives and programmable controllers must accommodate line-shaft applications and reduce stress on mechanical equipment to increase the life of the press.

Banta found, however, that some of the component-level control devices installed on its newer, foreign-made presses lacked the flexibility needed to upgrade the presses as technology evolved. As a result, efforts to modify the control system to increase productivity resulted in system errors and excessive downtime. And Banta’s maintenance engineers had difficulty getting replacement parts and service for foreign components. Even routine maintenance became a time-consuming and costly process.

Solving these problems required a comprehensive power control upgrade. For that, Banta’s engineering and maintenance superintendent, Gary M. Simo, turned to Werner Electric and Press Control Services, a Houston-based web offset integration specialist and a distributor of Rockwell Automation’s Allen-Bradley line of industrial control and automation products.

Turning to Rockwell Automation was a logical choice, according to Simo, because of his past satisfaction using that company’s products. “Over the past 30 years, I’ve specified and purchased Allen-Bradley products whenever possible,” Simo said. “And for more than 15 years with Banta, I’ve always been able to rely on Werner Electric for technical support and expertise when I needed it.”

To decrease installation costs and increase uptime, Banta installed Allen-Bradley On-Machine products whenever practical, from the press room through the bindery. Allen-Bradley NEMA components, including Bulletin 800 Push Button Stations, Bulletin 500 Contactors, Bulletin 1494 Disconnect Switches, and Bulletin 500 Starters applied both on the machine and within control panels, were integral to the upgrade that Rockwell recommended. Moreover, deploying industrial controls and hardware directly on a machine, rather than in centralized cabinets, significantly reduced installation time and associated costs by up to 30 percent.

When the press needed to be remanufactured in-house, the upgrade was streamlined by Allen-Bradley integrated panels housed in custom control cabinets. In the facility’s chiller plant, motor control centers fitted with Allen-Bradley Bulletin 500 NEMA starters also helped accommodate upgrades and meet changing electrical and mechanical requirements.

Banta selected the Rockwell Automation electronic line shaft components for their ability to provide precise web tension control. Allen-Bradley ControlLogix controller and high-powered DC drives replaced the gears, clutches, belts, and pulleys associated with mechanical systems. Now, from control panel, press operators electronically set web tension with a precision not possible with a mechanical system.

Since incorporating the Rockwell Automation control products, Banta has significantly decreased the make-ready and changeover time on its presses. Smooth, precise motor control has reduced equipment wear and tear, and the system’s advanced diagnostics have enhanced overall system reliability while reducing maintenance requirements. Additionally, readily available NEMA products, combined with local service, have simplified maintenance and upgrades on the foreign-built presses.

“In the deadline-driven print industry, where continuous operation is essential, it’s critical to find a supplier who can provide a quality solution with local support,” Simo said. “The reliability and flexibility of Allen-Bradley products, combined with the superior service provided by Werner Electric have helped us achieve the throughput we need to achieve our customers’ objectives.”

Overall, says Simo, Banta’s uptime has increased nearly three percent since the upgrades were completed. Most importantly, the Rockwell Automation power control products are designed to quickly and easily accommodate future system upgrades needed to exploit technological advances and continuous-press design improvements for years to come.

More information on Rockwell Automation’s Allen-Bradley brand of products is available by contacting Rockwell Automation Inc, 1201 S. 2nd St., Milwaukee, WI 53204; calling 414-382-2000; or visiting www.ab.com.