The most sustainable machine is often the one already running
In an industry shaped by innovation, automation and ever-shorter technology cycles, older production systems often fade into the background. Yet practice tells a different story: well-engineered lines kept in shape through preventive maintenance can run reliably for decades — economically, stably and efficiently.
A striking example stands at the Delmenhorst print house, where a Ferag insert drum (Ferag ETR-M) from 1991 still processes weekly papers with a high number of inserts today. What sounds like a technical curiosity is in fact a remarkable example of sustainable production systems in practice.
A production line with history
The original line was delivered to Kieler Nachrichten in 1991. Over the years it has been continuously expanded, modernized and adapted to new requirements. Today it includes:
- 20 insert feeding stations via Ferag Rollstream
- online feed of the main product directly from the press
- further processing via three modern Ferag Multistack MTS2 cross-stackers
- a semi-automated insert management system called “Prod-Plan”
“Prod-Plan” — production practice in action
A special feature of the line is the Ferag “Prod-Plan”. This semi-automated system organizes the sequence and combination of inserts before production begins. During production, the start and stop points of individual inserts are controlled automatically via counts. Notably, in this form the “Prod-Plan” is now in use only in Delmenhorst.
Preventive maintenance as the basis for system-wide stability
The long-term performance of the Delmenhorst environment rests not only on the robustness of individual machines but on consistent, structured care for the entire equipment landscape — in short, on preventive maintenance across the line.
As a specialist for print finishing service, Ferag Deutschland GmbH maintains not only the ETR line but also modern systems such as a Ferag RSD 20in1 insert line (built 2020), a cutting line with SNT-U, and current feed stations for press-waste disposal.
Under a service contract in place since 2011, specialists are on site in Delmenhorst around 12 weeks per year. This presence enables proactive technical support and helps develop existing systems in a targeted way. Across the interplay of older and modern lines, one thing is clear: what matters is not the age of the technology but the quality of its care.
Longevity is no accident
That a production line runs stably for more than 30 years is no accident. It is the result of several factors:
- solid mechanical and systemic engineering
- continuous modernization instead of replacement
- deep technical understanding on the operator side
- reliable service and maintenance structures
- and above all: preventive maintenance
Preventive maintenance means far more than avoiding breakdowns. It creates predictability, reduces risk and preserves the performance of existing systems over decades — extending production equipment lifespan well beyond expectations.
Conclusion: sustainability begins in operations
In times of rising investment costs and growing sustainability requirements, production equipment lifespan is becoming increasingly important. The Delmenhorst line shows that modernization does not always mean full replacement; often, great potential lies in preserving existing technology and developing it in a targeted way — modernization instead of replacement.
This is exactly where the value of preventive maintenance and continuous print finishing service shows: the foundation for proven systems to keep working stably, economically and productively, even after decades. A textbook case of sustainable production systems.
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