Posts Tagged ‘string bundler’

Here’s to Flyboys, Printer Talk, and Web Breaks

Sunday, January 24th, 2010

In a previous blog post, I referred to catching the printing bug as having printer’s ink in your blood. There is something about printing that gets one hooked. You can stray away from printing, but eventually you’ll circle back around and find yourself umbilically attached.

In my case, my printing career began right out of high school. I heard from a friend that a newspaper printer was hiring. I was the second to lowest employee on the totem pole, just ahead of janitor. I was a jogger. I think the hourly wage in 1968 was around $.75, maybe a buck and a quarter, I don’t really remember for sure. A jogger’s job was to stand at the delivery end of the press and scoop his hand between the conveyor belts, gather a stack of papers, and place them on the string bundler. There was a kicker that would knock a paper a little askew every 50th signature. This way we knew how many papers we were stacking. When the right quantity was reached the flyboy, (another name for jogger) pressed the foot pedal on the bundler. Heaved the bundle by hand over to a pallet, and scrambled back to the press to do it all over again.

Soon, because I looked bright enough, I suppose, they began teaching me how to make plates, hang the plates on the press, shaft the paper rolls, and fill ink trays.

OMG -- that really smells bad, and not in a good way.

It was dirty work, and because I was still the low man, I usually pulled the dirtiest jobs. When I think about it, I can still remember the smell of the developer, the ink, and even the paper.   The developer fluid was the most pungent. It made the entire press area smell bad. With today’s presses, they’ve either done away with plates, or plates are processed in a totally contained plate processor that doesn’t smell. Not at all. Whew — I thank you, my nose thanks you, and my clothes really thank whoever invented that dandy machine.

Part of the reason I chose a career in printing was because I thought it was a stable industry. After all, people will always need to get things printed — right? What I didn’t count on were all the technological changes in the business. Now they happen so quickly that it puts a kink  my neck as I whirl around  just trying to figure out where they are coming from next.

Negotiate This

It feels like Han Solo negotiating the asteroid field in the movie Star Wars. When he found what he thought was a nice safe cave to land in, it turned out he was very, very wrong, and barely escaped with his ship, friends, and life. I’m not saying that printing is life threatening it’s just difficult to know which way to go.

I was doing a press check at a web offset printer the other day. The presses are ever-so-more sophisticated than in my cub days. Many of the adjustments can now be done off of a computer console which keeps the press operators from running back and forth turning ink keys or adjusting registration.

Other things have also improved, for example, web breaks were common in my day. A web break occurs when the paper coming off the roll snaps apart. Snap is the right word but it doesn’t do justice to the event. It’s like a starting gun was fired. Pressmen scrambled like the Keystone Cops to get to and whack the big red STOP button. The goal was to limit how much re-webbing they’d have to do. No one breathed until they found out how much tail was left to splice before the whole (*@#&) press had to be re-webbed.


If the broken web wasn’t caught fast enough, it would take precious time, and many four-letter, red-faced printer words to fix it. Mule skinners had nothing on printers, I can tell you.

Today’s web presses have sophisticated roll changing systems that not only automatically splice, but keep a constant tension, so that the web won’t suddenly jerk when a roll bump suddenly happens. Have web breaks been completely eliminated? Ha, it just means that they happen less frequently. Are there fewer emissions of printer talk? Double ha! Web breaks aren’t the only things that go wrong. I like to say that printing has so many things that can go wrong it’s a miracle anything goes right.

One thing that hasn’t changed though is the job of jogger. The joggers are still there at the end of the press scooping up the printed press signatures and taking them to the pallet. My hat’s off to joggers. At least something, so far, has remained the same.

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The Way Printing Used to Be in 1968

Friday, January 23rd, 2009

I’m not just talking through my hat here. Today I can’t help but remember what the print world was like when I was green.  I was eighteen, it was the summer of 1968 and I was working for Hi-Color Lithographers, a newspaper printer in Tucson, Arizona. I was hired as a fly boy and a year later became an assistant pressman. A fly boy’s job was to stand at the end of the press, scoop up newspapers  as they came off the delivery, rush over to the string bundler, step on the pedal and backup quickly to prevent fingers getting tied up with the newspapers. I learned this lesson the painful way. I then had to take the packages over to a pallet and stack them so they wouldn’t fall over when the pallet jack moved it. That accomplished, I had to rush back to the delivery end of the press and scoop up another load before they all dumped on the floor. I did this all day long. Boring, boring, boring.

When the press ran low on paper I had to go over to the area where we stored the half-ton rolls and roll them toward the press. I was taught how to jackass a turn by running the roll up on a quarter inch thick, approximately one foot square of plywood. This allowed the roll to pivot. Otherwise it would take six men to turn the roll.

Once I aligned the roll of paper with the press, I had to knock out the wooden chucks that keep the cardboard core from collapsing.  I had to muscle a heavy iron shaft, run it through the core, and tighten metal core cuffs to prevent the roll from slipping on press. Then came my favorite part. I got to push the button to move the hoist over to the shafted roll. After securing the hooks to the shaft, the hoist was employed again to lift the roll onto the press. I had to make sure that it fit in it’s grooves, and ta-da, we were ready to keep printing.

Needless to say, this kind of manual labor has largely been replaced with automated systems. I doubt that any web printer uses plywood pivots any more. Instead they have modified fork lifts that grab the rolls around the middle with curved arms to haul them to the press.

I’m not sure why I wrote this today. Maybe the rain outside my office window is making me feel nostalgic.

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