When you get a lemon, make lemonade. The project team working on a new printing facility in Kent, Wash. took to heart this classic reflection on what to do when something goes wrong. And the results were remarkable.

Horvitz Newspapers, based in Bellevue, Wash., wanted to consolidate the printing of its two daily newspapers, the Eastside Journal, and South County Journal, six weeklies, and its commercial printing operation, including the printing of Investor's Business Daily and Seattle Weekly, at its South County Journal production facility in Kent, Wash. This consolidation would result in a full print schedule; therefore, it was critical that the manufacturing function drive the layout of the facility.

The initial plan was to expand the existing facility so the client could add a new press and accommodate additional packaging area. However, as the planning process developed and the city review process started, the costs the city would impose on the project and the review time caused by the building's proximity to the Green River became unacceptable.

That was the lemon. The lemonade is the design that resulted from building a separate structure at the back of the property. By building a detached facility, the costs imposed by the city were significantly reduced and the river issues disappeared. However, working within the project budget, the area constraints of the available site, and the schedule delays due to the redesign presented new challenges.

Because the available area was not as large as initial programming called for, the first hurdle was simply fitting the equipment in the space. The Horvitz Newspapers team and Chuck Blevins & Associates were forced to find creative solutions for space utilization and equipment layouts. To create enough space within the building footprint, the team settled on a two-story core area for offices and the computer-to-plate room.

The second hurdle was staying on schedule despite project delays. The tight schedule often precluded time to wait for equipment suppliers to create drawings and alternatives. However, CBAssociates' technical equipment layout expertise meant they could develop detailed layouts including conveyor paths. This allowed the Horvitz team to evaluate different alternatives and to select those they felt best met their needs—and still stay on schedule.

For example, when it became critical to determine how the packaging and dock equipment would be laid out for the Horvitz Newspapers publications and for the unique requirements of Investor's Business Daily, turning around layouts quickly proved invaluable in speeding up decision making.

Another creative solution can be seen in the project team's response to Horvitz Newspapers' goal of locating the computer-to-plate room as close to the press as possible, despite the constraints of a two-story building.

The solution was to locate the computer-to-plate room on the second floor with a bridge connecting it to the press catwalk. The operators will exit the plate room and walk across the bridge to the press deck.

When analyzing this concept, it was determined that 70 percent of the plate changing activity would be on the upper level of this tower press. This meant that the bridge concept not only made it easier for the operators, but also was more efficient.

Initially the building will house an eight-tower, two-folder DGM 440-3 press, with 10 right-angle reels, an online Heidelberg 630 inserter and online labeling to Quipp stackers. In order to maximize the use of the site, the facility will be built to accommodate a press expansion of eight additional towers, two additional folders, a second inserter and the associated stack/tie lines.

The 56,000-square-foot facility will be operational in the summer of 2002.

Although the design was driven by the equipment requirements, it should not, and did not, preclude good architectural design.

The facility will be seen from a major intersection and an adjacent freeway. Passing motorists will see a copper-colored metal arching press bay wall that incorporates plenty of glass. Windows measuring 24 feet in height and a total of 60 linear feet along the press bay wall provide passing traffic and pedestrians glimpses of the operation inside. Regardless of the angle at which the building is viewed, the strong copper and concrete forms will create an identity for the newspaper that is both interesting and pleasing. It will be a functional production building, but with a bit of flair.

Providing a good environment for their employees is important to Horvitz Newspapers. Large windows will allow natural light in the work area and lunchroom. The use of materials that are easy to keep clean, and the generally open and bright atmosphere will help make this a comfortable place to work.

The facility design and the new, highly automated equipment will increase the efficiency and the cost effectiveness of the operations. It will allow the company to consolidate the printing of all publications, to print Investor's Business Daily and Seattle Weekly, and to expand commercial and direct mail capabilities and capacities.

And that's a pretty sweet recipe for success.