St Ives - Compressor systems eliminates misfeeds

A computerised suction and blast air system developed by Busch (UK) has been installed at St Ives (Peterborough), where it has increased line speeds, virtually eliminated misfeeds and achieved payback in a year. The bindery handles about four million magazines a week, including The Economist.

St Ives had been faced with mounting maintenance problems on the 60 vacuum and pressure pumps which powered six Müller Martini 300's and two 301's stitching lines, each with eight feeders and four inserts, as well as a perfect binder with 18 feeders and six inserters. Maintenance was costing £500 a week, and 15 to 20 pumps were being overhauled each year up to £1200 a time.

The six 300's each needed six pumps at 162Kw in total and the two 301's six pumps at 84kW, while the perfect binder needs 28.2kW. This total demand was met by up to six Busch pumps running at a maximum of 95kW. Electricity savings totalled £23,000 in the first year, with maintenance savings of around £50,000 a year.

"We've been delighted with the new system" says Geoff Rice, Chief Engineer. "St Ives has ordered other systems for the plants in Caerphilly, Roche and Plymouth.

The Busch system is installed in a separate area of the bindery, unlike the previous installation where pumps were attached to floor level to each piece of equipment.

"The old pumps would run 24 hours a day, but the Busch system cascades in when the pumps are required," said the Bindery Manager, "My staff have a much better working environment too, and it's dust free, much quieter, with no oil on the floor and plenty of clean air!"

The Busch system's consistent pressure and vacuum services have increased machine speeds from 10-12,000 to 15,000 copies an hour. Misfeeds from the previous unpredictability of supply have been virtually eliminated, say St Ives.

The system assesses the bindery's needs every four seconds via a computerised control panel, which automatically keeps production levels constant, starting up the next available pump should the need arise.

The system recovers heat at a maximum rate of 42kW an hour, sufficient to provide a hot air flow to the building.