Publishers Printing and the G. F. Puhl Company to join forces in a Multi-million dollar Scrap Paper Collection System Upgrade and Expansion

Publishers Printing Company, one of the largest publication printers in North America and headquartered in Shepherdsville, Kentucky, has chosen the G. F. Puhl Company of Goodlettsville, Tennessee to lead their massive Paper Recycling System Upgrade and Expansion at their Lebanon Junction, KY Facility.

In keeping with their storied family tradition and overwhelming commitment to both customers and employees, Publishers realized the need to have a State of the Art Recycling Program. This will not only allow for optimum productivity, but will allow for more energy efficient transfer and processing of their scrap paper and other waste materials, allowing for a significant internal ROI.

Upgrade and Expansion Description

Puhl Company is to construct two (2) Dual 20’-0” Diameter Paper Handling Cyclones rated for 78,000 CFM each and install them in the new Baler Room Penthouse currently being constructed. The Press and Finishing Department’s Waste Paper from throughout the plant will be conveyed via Spiral ductwork and introduced into the Cyclones via numerous Puhl Blowers. Each Waste System is equipped with Inline Divert Valves for Redundancy.

The paper will then travel spirally downward through the Cyclone and into two (2) Horizontal Balemaster® Auto-tie Balers. As the paper spirals downward, the remaining dirty air will be removed through 72” Diameter Return Air Ductwork and sent to be cleaned.

The FARR APC® Filter Company, out of Jonesboro, Arkansas, will supply two (2) Gold Series GS72 Filter Units which, with their patented Poly-tech Media Cartridges, will yield a filtration efficiency of 99.99% @ 1 micron. A Balance Blower will reintroduce this filtered air back into the plant to offset any negative internal pressure.

To address any static electricity issues, Puhl will install Ionix Static Suppressors. These devices will treat the charged particles as they travel through the spiral ductwork, effectively neutralizing the static electricity.

Another significant ingredient in this system is the addition and implementation of a VecoPlan Rotary Grinder Shredder. VecoPlan of High Point, North Carolina, a long time leader in waste reduction technology, is increasingly making their presence felt in the Paper and Corrugated Industries. The VecoPlan Rotary Grinder Shredder incorporates a low speed, high torque, low noise, ram feed single-shaft rotary operation, and is controlled by a state of the art HMI Touchscreen Control Panel. As a result of this technology, Publishers will not only realize enormous annual energy savings, but they will be able to process all slab waste, rolls, butt rolls, cores, sheets, signatures and corrugated through one machine. Should a customer require confidential shredding, a simple 20 minute screen change will allow for this, and the shredded waste by product will meet NAID specifications for document destruction.

The entire Trim Collection and Recycling System will be monitored and controlled by an Allen-Bradley PLC system, complete with Ethernet communications between the PLC processor and peripheral devices such as touchscreens operator interfaces. Remote support, should it be required, will be provided by an Ethernet modem, allowing access to the intelligent components of the system from nearly any remote location. This system will be designed and constructed by the G. F. Puhl Electrical Engineering Department.

As you can see, Publisher’s Printing is a dedicated company with a focus not only on the present, but on the future. This endeavor allows for the addition of two (2) future Perfect Binders with Trimmer Stations, two (2) future Saddle Stitchers and one (1) Flat Bed cutter.

The G. F. Puhl Company is proud to join all parties involved to contribute to Publishers Printing’s desire to deliver the best products and services available.