Goss International has launched a comprehensive press controls upgrade program at Zehnder Print AG in the St. Gallen region of Switzerland. The project involves installation of new hardware and software systems to deliver more advanced capabilities to an existing 2x1 Goss Universal press.

The Goss Universal shaftless press at Zehnder Print AG, comprising six four-high towers, one folder, one dryer and eight reelstands, is currently used for both heatset and coldset production, with demand for the former growing steadily in recent years. The turn-key upgrade project involves replacing existing Allen Bradley press controls and proprietary systems to create an open systems architecture with universal compatibility.

Working in cooperation with Harland Simon, Goss International will replace existing desks and separate quality control hardware with three new combined consoles to manage all aspects of print control, including presetting, production planning, monitoring and reporting. Electronic modules in each printing unit as well as electrical boards for the control of inking and dampening will also be replaced with modern JDF-compliant systems.

The project will result in automation and integration of all press auxiliary systems, including reelstands, color, cut-off and web tension controls, providing operators with new levels of operational convenience and flexibility. Via a standard Ethernet network and remote input/output controls at the units, the entire press will also be supported by a remote diagnostics service, enabling Goss International technicians to provide Zehnder with round-the-clock assistance in the case of technical difficulties.

"The new electrical architecture is designed for low maintenance with redundancy of the existing systems and components as required," explains Stéphane Jaunasse, Goss International Customer Service Manager. "With every aspect of the press production embedded into and driven by one open and accessible system, the 10-year-old Universal press at Zehnder Print will be upgraded to a modern user-friendly high-quality printing solution, providing all the capabilities the company requires for its clients' diverse range of production demands."

With work already underway, Goss International is working in close cooperation with the customer and other parties in managing the project to ensure minimal disruption at the plant and uninterrupted production. The existing system will remain operational until the new controls infrastructure is fully tested, both at the Goss International facility in France and then again on site at Zehnder Print.

Zehnder Print AG is widely known in Switzerland as one of the leading providers of high-quality printed publications. As well as international titles such as International Herald Tribune and The Wall Street Journal, the award-winning company prints 32 weekly newspapers and a variety of magazines for national distribution. Heatset printing is assuming ever greater significance within Zehnder's product portfolio as the company continues to gain semi-commercial work such as inserts and advertisement sheets for, among others, leading Swiss watchmakers. This was a key factor leading Zehnder to the decision to upgrade.

According to Alexander Honsel, production director at Zehnder, confidence in Goss International was also crucial to the decision, "We have long-term positive experience with Goss equipment, and the team from Goss International understood our current requirements very well. They have come up with a solution which allows us to eliminate components as they become obsolete while providing a growth path for any necessary future additions. We're very confident of having chosen precisely the right package to modernize and enhance our capabilities to see us through the next ten years of production from our existing Universal press."