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PMP opens doors of directory supersite for LIA tour

Thursday, 28 July 2011
By Print 21 Online Article

LIA members were awarded with a behind-the-scenes tour of PMP’s Chullora site as the new sized Sensis telephone directories ran off the line.

Three tour groups were given a walkthrough of plant operations on 27 July as the new sized White Pages ran through the three 64pp Heidelberg Harris web presses at 2,200 feet per minute.

Stopping off at the control room, the groups were given an overview of how the entire operation has moved to touch screen technology, that can control the finer points of the production line from ink to wastage control.

PMP’s 2.2-hectare Chullora site is a self-contained directory print plant where the entire run is completed in house from print to finishing, including servicing.

To produce around 30 million Sensis directories annually, 38,800 tonnes of paper flows through the plant every year. It also goes through 770 tonnes of ink, and 149 tonnes of shrink-wrap.

All three 4-colour lines are now printing the new sized White Pages, which has become the new standard. No changes needed to be made to the presses or bindery to accommodate the new format.

Tim Burt, operations manager for PMP Chullora gave a post-tour breakdown once all groups had merged, noting that the challenges it is facing are consistent with the rest of the printing industry.

The plant has had to bring in lean manufacturing initiatives and deal with an aging workforce. Manning the print lines are 120 staff, of which 22 have over 20 years of service and one pre-press operator has worked the directories line for 52 straight years.

Around 8 trucks leave the Sydney plant every day, each carrying an average of 14,000 books at a time.

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