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How automation transformed newspaper production at India’s ABP

“Adapting to changing consumer preferences and leveraging new technologies is crucial for survival and growth of the newspaper printing industry,” Pradyumna Mitra, general manager – engineering, ABP, told participants at Wan-Ifra's recent Indian Printers Summit.

Mitra’s presentation focused on the benefits of automation for newspaper printing.

“We must adapt to new challenges. Recent wars and global disruptions have only contributed to increased production costs, particularly through supply chain issues,” he said during the summit.

The impacts on the industry have been significant.

Increased printing costs, higher newsprint prices, and logistical challenges have emerged as key issues. Additionally, the growing adoption of digital news consumption has led to negative growth in print revenue, making it clear that traditional methods of production are no longer sustainable in their current form.

The shift towards automation in newspaper production is crucial for survival, Mitra said.

Leveraging automation in prepress to enhance efficiency

ABP, which publishes popular dailies such as Anandabazar Patrika (Bengali) and The Telegraph, has taken significant steps towards automation, particularly in the prepress segment. Mitra highlighted some of the tools they have implemented to streamline operations.

Pro Image OnColor plugin: It provides editorial teams with the ability to process images faster in an automated mode, without human intervention. OnColor can process a high volume of images quickly to meet publishing standards within tight deadlines. The tool’s workflow provides fast and consistent results, significantly reducing ABP’s time to press, Mitra said.

AI-powered Retouch4Me plugin in Adobe Photoshop: The plugin automates the photo-editing process with minimal manual intervention. It applies machine learning models to analyze images and make retouching decisions based on skin tones, texture, and lighting patterns.

Adobe Generative AI: This tool is integrated into ABP’s workflow to automate image editing tasks such as removing unwanted objects and adjusting exposures in real-time. Mitra described how tools such as Generative Remove, Camera Raw Filter, and Parametric Filters, help optimize tasks such as image retouching and adjustment.

Automated tools in production and press

Beyond prepress, ABP has leveraged automation in production and press operations.

Automation of advertisement file processing, which ABP implemented about a year and a half ago using OneVision Asura pre-flight software, has allowed ABP to efficiently manage a high volume of ads.

“We also implemented script-based PDF content validation, which helps us ensure accuracy in text elements such as dates and metadata,” Mitra said.

In terms of press operations, automation is helping ABP reduce waste. The Auto Fan Out correction software has been integrated into the Pre-Press NewsX workflow to improve overall print quality. The system automatically adjusts offset values based on individual print unit behavior to improve consistency and reduce material waste.

Automation tools can manage complex files with more than 10,000 images, reducing delays and waste during peak production hours, Mitra said.

Cutting costs with automated energy management solution

Energy management is another area where automation is helping ABP cut costs and improve efficiency.

Frequent grid power interruptions had previously resulted in mechanical failures and downtime during press operations, causing loss of critical production time at night.

“To avoid this, we had to run generators continuously at night during high production periods. This led to high fuel costs and frequent servicing of the generators,” Mitra said.

“We installed a dynamic UPS system with PLC-based automation to ensure seamless power transitions, which helped us reduce fuel costs and eliminate unnecessary stoppages,” he added.

Integrating energy meters and real-time data acquisition systems has helped the publisher better monitor its power consumption from solar, diesel generators, and grid systems. This approach allows ABP to identify non-critical areas and reduce energy waste.

Electricity costs are a major concern for any printing plant. In most cases, HVAC systems account for 40% to 50% of the overall electricity bill, depending on weather conditions. Continuous HVAC operation also shortens the lifespan of rotating components such as pumps, chiller compressors, and H-U motors. However, with the help of IoT-based sensors and data analytics, ABP now collects real-time data to monitor system performance more effectively.

Waste management using IoT-enabled solutions

Automation has proven beneficial for ABP in waste management as well.

“Traditionally, waste copies are collected manually, weighed, and sold to agencies,” Mitra said. “However, this process is labor-intensive and inefficient.”

To address this, ABP is in the process of implementing an automated system to streamline the logistics of waste handling. The proposed system will involve a conveyor connected to a compacter, reducing human intervention and improving the sale value of waste.

ABP is also evaluating IoT-enabled smart containers for further reduction in manual handling. Additionally, the publisher is conducting a feasibility study to automate its 48,000-sqft warehouse at the Barasat plant in Kolkata, for incorporating automated guided vehicle (AGV) technology.

“This system ensures error-free operation, reduces waste, and improves efficiency with minimal human intervention. Real-time tracking of material flow allows warehouse personnel to make informed decisions about stock levels and optimize operations,” Mitra said.

‘Automation is key to our journey towards sustainability’

Mitra highlighted the role of predictive maintenance in extending spare serviceability and preventing unplanned breakdowns.

“We have conducted a pilot project using IoT sensors and AWS cloud data analytics to acquire real-time temperature and vibration data from our print couple motors,” he said. “This pilot has yielded encouraging results, and we are optimistic about the potential for predictive maintenance using AI and machine learning.”

However, Mitra acknowledged there are challenges in setting up a robust data acquisition infrastructure and managing the large volumes of data required.

“We must take advantage of the latest developments in IT and electronics hardware,” he said. “Automation is key to our journey towards sustainability.”

He concluded by highlighting the potential for collaboration between technology users and suppliers to develop cost-effective, smart, and customized solutions.

“In this era of connectivity, automation can play a critical role in helping us achieve long-term sustainability in the newspaper industry,” he said.

aultrin.vijay@wan-ifra.org 

(First published on Wan-Ifra)

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Wan-Ifra announces winners of South Asian Digital Media Awards 2021

Malayala Manorama’s manoramaonline.com bagged the ‘Best in News Website’ South Asian Digital Media Award for the third time in a row. Among the winners are The Hindu, Hindustan Times, The Quint, Mojo Story, NDTV Convergence, Times of India Digital, and Sakal.

The 2021 awards in their fifth edition received more than 140 entries, a record jump of close to double the number of entries in the previous year. These awards, presented by Wan-Ifra, recognize South Asian publishers who have delivered unique and original digital media projects in the last 12 months. These projects inspire us all, from new approaches to digital subscriptions to impactful native advertising campaigns. The ‘Gold’ winners automatically enter Wan-Ifra’s World Digital Media Awards competition.

Winners of South Asian Digital Media Awards 2021

The winners of South Asian Digital Media Awards 2021 for the different categories are -

Best News Website (or) Mobile Service

Gold - Manoramaonline.com, Malayala Manorama

Silver - thequint.com, The Quint

Bronze - bloombergquint.com, Quintillion Business Media

Best Use of Online Video

Gold - Life in an Auto - The Inspiring Story of 74-year-old Sole Breadwinner, Desraj Jyot Singh, The Quint

Silver - Girls on a Mission, People Like Us Create (PLUC)

Bronze - A Night at India’s Largest Farmer’s Protest, BBC News

Best Newsletter

Gold - Times TOP 10, Times of India Digital

Silver - The India Cable, Foundation for Independent Journalism

Bronze: Here’s the thing – Weekly Members-only Newsletter, Spunklane Media.

Best Data Visualization

Gold - West Bengal Elections 2021, NDTV Convergence

Silver - Covid-19 pandemic - Full Coverage, NDTV Convergence

Bronze - Kerala Assembly Election 2021, The Mathrubhumi Printing & Publishing

Best Reader Revenue Initiative

Gold - HT Codeathon, Hindustan Times

Silver - Support The Wire, Foundation for Independent Journalism

Bronze - Freedom Sale 2021 – The Hindu Group, The Hindu

Best in Audience Engagement

Gold - Bring Back Milk Bikis Campaign, The Hindu

Silver - Teen Goshti, BBC News

Silver - Kissan Protein Champs – Knowledge Series & Brain-teasing Activities, The Hindu

Bronze - Njanoru Naran, M M Publications (Vanitha)

Best Podcast / Digital Audio Project

Gold - Sakalchya Batmya / Daily Sakal News, Sakal Media Group

Silver - Club FM Cinema Katha, The Mathrubhumi Printing & Publishing Co. Ltd.

Bronze - Vivechana, BBC News

Best Brand Marketing Campaign (for News Brands)

Gold - Doctor’s Day Campaign – Hindustan Times

Silver - Neel Barir Lorai – Anandabazar Patrika

Bronze - HT Fresh – First Voice, Last Word – Hindustan Times

Best Special Project for Covid-19

Gold - On The Road with the Pandemic: Counting India’s Uncounted Covid Deaths, Mojo Story

Silver - Hindustan Covid Actions, Hindustan Media Venture.

Silver - Covid-specific Jagran Dialogues Series, in collaboration with Ministry of Health & Family Welfare and Unicef India, Jagran New Media

Bronze - BBC’s coverage of Covid in India, BBC News

Best Branded / Sponsored Content Campaign

Gold - Unacademy Let’s Crack CSE, The Hindu

Silver - HT Codeathon, Hindustan Times

Silver - Break the Taboo, The Daily Star

Bronze - Bring back Milk Bikis, The Hindu

Bronze - HTLS 2020, Hindustan Times

The entries were evaluated by an international panel of jury which included – Adam Tinworth, Digital Publishing Consultant, UK, Alberto Lucas López, National Geographic, Angela Robson, multi-award-winning TV, radio and print journalist, Corinne Podger, Reuters & BBC Certified Consultant, Australia, Dickens Olewe, Journalist, Kenya, Emanuel Karlsten, Media Consultant, Hans Peter Janisch, newspaper designer and consultant, Iryna Vidanava, independent online media consultant, Belarus, Jacqui Park, journalist, editor and media strategist, Jerusha Raath, Head of Brand Studio, 24.com, Juan Velasco, Founder and Creative Director of 5W Infographics, Michael Cooke, consultant and editor, Murdoch Davis, consultant and editor, Rob Montgomery, Mobile Journalism consultant, Lucie Lacava, Design Consultant, Steve Yelvington, Media Consulting and Training, Kuek Ser Kuang Keng, Award-winning digital journalist, Kuala Lumpur, Rakesh Dubuddu, founder and chief executive officer, Factly, Chhavi Sachdev. Storyteller - Podcast Producer, Editor, Aniruddha Pawade, Podcast Consultant, Gurman Bhatia, Independent Information Designer, Prem Koman, Narrative & Storytelling consultant, Kavita Chandran, Thomson Reuters Foundation and Sambit Pal, Associate Professor, International School of Broadcasting and Journalism.

The winners will receive their awards virtually at the upcoming South Asian Digital Media Awards 2022, which will take place from 8-10 March.

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