kicker

A kicker is a mechanical arm or gate positioned at the end of a newspaper press delivery line that periodically strikes or deflects falling printed sheets sideways into a gathering wagon or bundle cart. As newspapers exit the press in a continuous stream, the kicker engages at timed intervals to kick a predetermined number of sheets (typically 25 to 50, depending on paper weight and bundle specification) laterally away from the main delivery stream. This creates discrete stacks that can be easily gathered, strapped, and prepared for dispatch.

The device works in concert with a counting mechanism or master counter that tracks individual sheets passing a sensor point. When the count reaches the target bundle size, the kicker is triggered pneumatically or hydraulically to swing into the paper path for a fraction of a second, then retract. The timing must be precise: sheets must be moving slowly enough to be deflected cleanly without tearing, but fast enough that production is not impeded. Most modern kickers are pneumatic rams mounted on the paper guide frame, with adjustable dwell time and stroke length.

Common problems and variants

Kicker failure typically manifests as incomplete bundle gathering, with sheets scattering rather than stacking neatly, or sheets being jammed in the deflection zone. This often stems from worn pneumatic seals, misaligned timing relative to the press drive, or paper moisture content that affects rigidity and deflection behavior. On some presses, especially older hot-ink models, a simple mechanical cam-driven kicker arm was used instead; these are less reliable but still found in service. Some presses use a rotary diverter gate instead of a linear kicker, rotating in and out to direct paper to alternate collection points.

The term "kicker" comes directly from the action: the device kicks the paper. It sits downstream of the folder (if the press is folder-equipped) or the delivery fly on a flat-sheet press. Bundle size and kicker frequency are set during press setup according to the publication's specifications and transport requirements. Oversize or premium publications often require smaller bundles to prevent compression damage, while tabloid and small-format papers tolerate larger bundles.

Operators must monitor kicker engagement constantly during production runs. A sluggish or intermittent kicker will produce bundles of uneven size, creating sorting and mailing problems downstream. Most modern presses log kicker activation via the control system, allowing press managers to detect drift or failure before customer-visible quality loss occurs.