Production

The company’s Lincoln campus hosts a temperature- and humidity-controlled state-of-the-art production facility that includes multiple sophisticated web presses controlled by a computerized command station from which all press operations can be tested and adjusted.

The facility also hosts its own platemaking equipment and bindery (Sandhills Publishing was a pioneer in the more efficient and environmentally friendly direct-to-plate process), as well as equipment for stitching and trimming.

Paper Rolls

Each paper roll weighs between 2,000 and 3,100 pounds. Sandhills uses different weights and textures of paper for the different publications. Our production facility is temperature and humidity controlled since both impact how well the paper runs through the press and bindery.

Paper Stacks

We maintain a six week inventory of paper—crucial in winter since paper mills are located in the north and weather conditions can prevent truckloads from arriving on time. The rolls of paper also need to acclimate to their environment before they are used. We use an average of 505,000 pounds of paper each week.

Ink Totes

Each ink tote contains an average of 2,700 pounds of ink and we use an average of 13,000 pounds a week. The ink totes in use are connected to pumps which send the ink through pipes to each press. Two types of ink are used, low tack for uncoated paper and high tack for coated paper.

Plates

Sandhills Publishing was a pioneer in the direct-to-plate process, saving time and materials during production and improving print quality. This efficiency allows for higher production and a smaller environmental footprint. All used plates are recycled.

Presses

Sandhills Publishing has one Goss Sunday press and one Goss G-18 press, with press speeds varying from 42,000 copies per hour to 55,005 copies per hour. The Sunday press has a number of automated features, including auto plate, and continues to set the standard for high-volume applications.

Control Panel

Each press is controlled from a fully integrated command station. From here, ink keys and ink ball speeds are adjusted as needed, as well as press speed and registration. Signatures or copies are checked throughout the run to ensure our quality standards are being met.

Roll Stands

During a run, the press is never shut down to change rolls of paper as we can splice a roll on the run. Splices are signaled so the taped splice can be pulled out of the finished product at the other end of the press at the stacker.

Bindery

The bindery assembles the pages of each publication quickly and efficiently. The finished product is either inkjetted with the address and postal barcode for the individual subscriber or boxed or shrink bundled in various counts for the bulk locations.

Stitching And Trimming

The stitching and trimming of each publication is automated for efficiency and speed. Each book is trimmed on three sides and the “stitch,” which resembles a staple, is actually produced from a roll of wire.

Product Stacks

Publications are printed and bound 24 hours a day, five days a week, and are distributed across the country as well as Canada. UPS picks up five times a day, five days a week and the postal verifier comes in every day to verify the mail so it can be loaded and sent on its way.

Recycling

As much as possible is recycled in the production facility, including aluminum plates, trimmed paper, and plastic wrap. Both bindery lines are connected to a baler where all the paper trimmings are gathered and tied into bales, which resemble a hay bale.

Safety

Employees perform inspections on each shift daily and weekly to ensure everything is in working order. Equipment is “locked out/tagged out” during maintenance and repairs so it can’t be powered up until the task is completed. All employees are required to go through a number of safety training classes annually.