We knew we were in trouble Tuesday morning. The machine that makes our printing plates had stopped working.
Plates are an essential part of the printing process. To over-simplify the process, the image of newspaper pages is burned onto a plate, a coated sheet of aluminum. The best way to describe making a plate is to think of a toaster. Put a piece of bread in, hit the lever and wait for the wires to heat up. A piece of toast pops out. Substitute bread for a three foot by two foot piece of thin aluminum and wires for a spinning laser and you’ve basically got it.
The plate is wrapped around a large cylinder on the press. Ink and water are directed toward the moving plate and transferred to another cylinder wrapped with a ‘blanket.’ The blanket transfers the image onto speeding half-ton rolls of paper which are mechanically assembled, cut and folded.
I guess there isn’t anything simple about the printing process.
A nearby newspaper helped us by making plates for our Wednesday edition. Nearby is a relative term, as our friends are located 45 minutes away.
Problem solved. Or so we thought.
Around 2:30 a.m. on Wednesday, one of the plates flew off the press while we were printing. We were stuck with no ability to make a replacement and no time to get one made by our nearby friends and make it to the Post Office in time for delivery.
At that point we had hundreds of newspapers printed. Unfortunately, we need thousands.
It’s never a fun day in The News-Banner office as we field hundreds of calls and walk-in customers asking about their newspaper. It’s an all-hands-on-deck kind of day.
While it isn’t fun, it is energizing to know the newspaper we print is a critical part of people’s day. It’s an honor that we don’t take for granted.
On the positive side, we talked to more subscribers than we would have on any other day. We always learn something about what people like and dislike about their newspaper. For example, I found out how important Saturday’s stock market wrap-up is. I always appreciate the feedback.
At one point during the afternoon, I began timing the gap between calls. We had a two minute respite only once. More often the calls were merely seconds apart.
Throughout the day what stood out was how understanding and gracious everyone was. Internal production issues quickly turn into external problems because they effect you, the paying customer.
Wednesday afternoon, we were right back at it, going through the same process to get plates made by our friends. This time, we ordered a second set — just in case.
Thursday morning the replacement part was delivered and was installed by early afternoon.
We are back to making toast.
The world is right again. At least for now. I’m not one to be overconfident.
Thank you for all of the calls. We appreciate everyone who stopped by the office, emailed or texted.
You reaffirmed that the work we do is important and the people we serve are wonderful.
For that we are blessed.
dougb@news-banner.com
