Quad Graphics

This is the second Quad Graphics plant to install a Westfalia AS/RS. The emphasis on efficiency gains through automation began in 2005, when Quad Graphics installed a Westfalia High Density AS/RS at its Lomira, Wis. plant.

Westfalia’s AS/RS at the Lomira plant, the largest single printing facility in the Western Hemisphere, streamlines and expedites print production. The system is designed with two S/RMs in each aisle, cutting the travel distance of the cranes in half. Coupled with center stationed infeed and outfeed conveyors, this system will provide extremely high throughput rates. The Lomira facility stores three different styles of pallets — plastic USPS, plastic 9-block and a wooden internal pallet - without the need for slave pallets. The 42,005 pallet position, high density automated storage system measures 776’ x 92’ wide and 107’ high. The system will contain four Storage/Retrieval Machines and 1,600 linear feet of conveyors.

Functions include conveyance, storage and sequencing for work-in-process materials. The system retrieves pallets of logs (bundles of signatures) and delivers them for binding. The S/RMs travel on rails between the rows of storage racks and accept 100 percent of Quad’s production requirements without human involvement.

“These new systems played a major role in helping Quad/Graphics realize their goal of building a highly efficient, highly flexible, yet space-saving and labor-saving facility,” said Dan Labell, President of Westfalia Technologies, Inc. "Quad/Graphics now has a plant that will certainly set new standards for the commercial printing market.”

“Westfalia has installed similar systems all over the world and are renowned for their quality, flexibility and dependability,” says Bob Douglas, a master electrician with Quad’s Corporate Facilities. "This system will meet our needs for many years to come.