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Series 2006 $1 SOI Production
By Greg McNeal, Bank Note Reporter
September 19, 2013

This article was originally printed in Bank Note Reporter.
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The Bureau of Engraving and Printing replaced two of the I-10 Intaglio (I-10) presses with Super Orlof Intaglio (SOI) presses in Washington, D.C., during 2007. A complete line consisted of a press for the printing of the back of the note (first process) and a press for the printing of the face of the note (second process). A complete line or both first and second process was replaced at the same time.

The SOI press had the potential to increase production by 56 percent due to the larger sheet size it could handle. The I-10 press used a 32-note sheet, while the SOI press could use a 32-note sheet or a 50-note sheet.

Both presses could run 10,000 sheets per hour. But, with the larger sheet size, the SOI press could produce 500,000 notes per hour vs. 320,000 notes on the I-10 press. Currently, the SOI presses are running 32-note sheets and all 2006 Series sheets were 32-subject sheets.

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Other differences include: the SOI press has a better integrated inspection system with 10 times the resolution of the I-10 press, it has the capability of printing one additional color, and it has a more precise ink control, which helps save costs by reducing ink usage. The SOI press also features a four-pile delivery system vs. a two-pile on the I-10 press, which reduces spoilage by having less weight (pressure) on the bottom sheets of each pile. And, the SOI press uses three printing plates vs. four printing plates for the I-10 press.

During the initial testing, adjustments had to be made to the SOI presses due to the differences in the two presses to get the quality the BEP wanted in the notes. The earliest $1 2006 Series SOI notes observed, as of this writing, were printed in DC during February 2008 and were the B/H Block Run 11. An SOI line was installed in the Fort Worth, Texas facility during 2008. The earliest FW SOI note observed, as of this writing, was printed during September 2008 and was from F/L Block Run 4 and L/L Block Run 12. For additional information see www.moneyfactory.gov/uscurrency/theproductionprocess.html

Series 2006 $1 notes were being printed in both facilities when the SOI presses were installed. $1 sheets were being printed on both the I-10 and SOI presses as demand required.

Unlike the $20 SOI note, which had a larger face plate number, there was not a noticeable difference in the $1 SOI note. This made the identification of $1 notes printed using the SOI press difficult. Collectors and dealers were identifying $1 SOI notes by the three plate number rotation for the face plate and back plate since this was the only noticeable difference in the production.

This presented a challenge because the only way to identify if there was a three-plate vs. four-plate rotation was to find new notes in consecutive number order. With the help of several collectors and dealers, a list of confirmed I-10 and SOI plate numbers from new packs of both I-10 and SOI press were identified and recorded. As face and back plate numbers were identified, they were added to the list as confirmed SOI or confirmed I-10 numbers.

The confirmed list of numbers made it possible to identify other numbers that were associated with either I-10 or SOI presses. Associated plate numbers were identified when an unidentified number was found on a note with a confirmed plate number. The key was to find a note that contained a confirmed face or back plate number. Over time, after reviewing thousands of $1 2006 Series notes and with help from collectors and dealers, a list of face and back plate numbers for both I-10 and SOI was compiled for both DC and FW.

One might ask why a plate number used on an SOI press could not also have been used on an I-10 press? The BEP’s practice of monitoring each plate produced very closely is why this is not likely to happen. Each plate is given a unique number that is recorded along with the press that it was used on, when it was placed on the press and when it was removed from the press. While it is possible for a plate to be removed and repaired, it will be returned to the press it was taken from or destroyed.

Since both the I-10 and SOI printing presses were producing $1 notes at the same time in both facilities, there is potential for a hybrid note to be produced. A hybrid note is defined as containing a plate number from one press on the face and the other press on the back. However, since the BEP has gone to great lengths to keep the sheets separate, as of this writing, none have been confirmed. It is believed that due to the adjustments that the BEP made for the SOI presses, the sheets had to be kept separate and printed on the same type of press (either SOI or I-10). These adjustments made it impossible for a sheet printed on the I-10 press to run correctly on the SOI press and vice versa. As a stack of sheets came off a press for the first process, they were labeled to identify the press they were printed on and when they were printed. They were dried for three days then sent back to the same line for the second printing process.

Currency Overprinting Processing Equipment and Packaging (COPE-Pak) is the third printing process. Stacks of 10,000 sheets (two half sheets stacked side by side) from both the I-10 and SOI presses are fed into the COPE-Pak presses. At this point in the printing process, sheets from both I-10 and SOI presses run the same on the COPE equipment. Since a normal Run consists of 200,000 sheets or 20 Stacks consisting of 10,000 sheets each, there is potential for a Run to contain notes from both I-10 and SOI presses. Using the list of confirmed and associated face and back plate numbers from both printing facilities, Blocks and Runs were identified as being printed on either the I-10 line, SOI line or a mixture of both. This possibility has left some Runs with a short production of SOI or I-10 notes.

It appears that after the FW facility installed and started using the SOI presses in September 2008, all production of the 2006 Series $1 note shifted to FW with the exception of the New York District, which continued being printed in DC until May 2009. This shift in production made it possible for a District to have notes from the same Block printed in both DC and FW. As of this writing, only one Block has been identified as having SOI notes from both facilities. That Block is from Richmond and it is E/E. SOI notes have been identified from Run 1 printed in DC and Runs 4, 7, 8, 9, and 15 printed in FW.

The following is a list of confirmed and associated $1 2006 SOI face and back plate numbers as of this writing for both DC and FW:

DC Face Plate Numbers: 120, 121, 122, 124, 172, 173, 174, 175, 235, 236, 237, 238, 239, 240, 242, 243, 246, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 272, 273, 274, 277, 280, 282, 292

DC Back Plate Numbers: 125, 126, 129, 131, 133, 134, 135, 136, 137, 138, 139, 140, 141, 183, 186, 187, 240, 242, 243, 285, 286, 287, 290, 293, 295, 297, 298, 299

FW Face Plate Numbers: 135, 136, 138, 139, 141, 142, 143, 144, 147, 148, 149, 150, 151, 156, 157, 160, 161, 165, 166, 167, 168, 169, 170, 171, 172, 173, 190, 191, 193, 196, 220, 222, 223, 224, 231

FW Back Plate Numbers: 82, 101, 102, 103, 111, 112, 114, 116, 118, 120, 121, 122, 125, 127, 129, 130, 134, 135, 136, 153, 154, 155, 159, 160, 161, 178, 179, 180, 181, 182, 183

To arrive at the percentage of SOI, I-10 or No Data for each Block, a Block was separated into Runs and Stacks. A full Block of non-star notes consists of 15 Runs with 200,000 sheets per Run. The 200,000 sheets per Run are broken up into 20 Stacks of 10,000 sheets per Stack. So a full Block of non-star notes would contain 300 Stacks (15 Runs * 20 Stacks). The Run, sheet number and Stack was identified for the notes observed and added to the data for the note.

All of the notes observed were then sorted by where it was printed (DC vs. FW), District, Block, Run and Stack. If the note was an SOI note, the Stack would be counted as an SOI Stack and vice versa for the I-10 notes. The percentages shown represent the percentage of Stacks based on the number of Runs in the Block. The following list identifies the 60 Blocks that contain SOI notes as of this writing. If a Block is not listed, all identified notes were from the the I-10 press. As you can see from Table 1, there are six blocks that contain 1 percent or less SOI notes. They are B/L, D/C and E/B from DC and F/L, J/B and K/D from FW. The following is a detailed analysis of each of these Blocks:

• B/L - printed in DC during April and May 2009. The B/L block was the last 2006 Series block for New York. Only five Runs were printed. Only one SOI note has been observed giving this Block a 1 percent SOI printing. For the last Run, Run 5 printed in May 2009, we have recorded one note from the last Stack which was SOI. The next to the last Stack has not been observed giving this Block the possibility of only two Stacks from the SOI line. Twenty-four Stacks or 24 percent of the 100 Stacks have not been observed.

• D/C - printed in DC during June, July and August 2008. The D/C Block was a full 15 Runs printed during three months of 2008. Only one SOI note has been observed, giving this Block a .333 percent SOI printing. Notes from stacks on both sides of the SOI stack have been observed as I-10 notes giving this Block the possibility of only one Stack from the SOI line. Fifty-two Stacks or 17 percent of the 300 Stacks have not been observed.

• E/B - printed in DC during April and May 2008. The E/B Block was a full 15 Runs printed during two months of 2008. Only one SOI note has been observed giving this Block a .333 percent SOI printing. It was from a Stack in Run 5. Notes from two Stacks after the SOI Stack have not been observed giving this Block the possibility of three Stacks from the SOI line. Seventy-three Stacks or 24 percent of the 300 Stacks have not been observed.

• F/L - printed in FW during September 2008 and April and May 2009. The F/L Block was a full 15 Runs printed during three months of 2008 and 2009. Only one SOI note has been observed giving this Block a .331 percent SOI printing. It was from a Stack in Run 4. Notes from Stacks on both sides of the SOI Stack have been observed as I-10 Stacks giving this Block the possibility of one Stack from the SOI Line. Thirty-four Stacks or 11 percent of the 300 Stacks have not been observed.

• J/B - printed in FW during October 2007 and February and March 2009. The J/B Block was a full 15 Runs printed during one month in 2007 and two months in 2009. Four notes from three Stacks of Run 10 have been observed giving this Block a 1 percent SOI printing. Notes on both sides of the three SOI Stacks have been observed as I-10 notes giving this Block the possibility of three Stacks from the SOI Line. Forty-three or 14 percent of the 300 Stacks have not been observed.

• K/D - printed in FW during March and October 2008. The K/D Block was a full 15 Runs printed during two months of 2008. Two notes from two different Stacks of Run 14 have been observed giving this Block a .667 percent SOI printing. Notes from the Stacks on both sides of the two SOI Stacks have been observed as I-10 Stacks giving this Block the possibility of two Stacks from the SOI line. Ninety-nine or 33 percent of the 300 Stacks have not been observed.

There are an additional 11 Blocks with less than 5 percent SOI printing. They are as follows:

• D/E - 1.333 percent - printed in FW during June, July and August of 2009.
• C/D - 1.923 percent - printed in DC during February and March of 2008.
• L/S - 2.000 percent - printed in FW during May and June 2009.
• D/D - 2.050 percent - printed in FW during June 2009.
• B/K - 2.333 percent - printed in DC during October and November 2008.
• F/P - 2.333 percent - printed in FW during June and July 2009.
• L/Q - 2.333 percent - printed in FW during April and May 2009.
• F/M - 2.667 percent - printed in FW during May 2009.
• F/N - 3.333 percent - printed in FW during June 2009.
• H/D - 3.571 percent - printed in FW during April, November and December 2009.
• D/F - 4.333 percent - printed in FW during August, October and November 2009.
There have been four star Blocks observed where a Run included SOI notes, one from DC and three from FW.
• G/* - printed in FW during April 2008 and December 2009.

There have been three Runs printed, one in April 2008 before FW started printing SOI notes and two in December 2009. The second Run (03200001-06400000) printed during December 2009 was a full 100,000-sheet production and was all I-10 notes. The third Run (06400001-06912000) also printed during December 2009 was a short Run of 16,000 sheets. Only five notes have been observed. They were all SOI notes. Based on the notes observed, the G/* block is 7 percent SOI (512,000/6,912,000).

• L/* - printed in FW during September 2007, November 2007 and November 2011. There have been four Runs printed, two before SOI presses were installed and two in November 2011. There have been eight notes from four Stacks reported that were SOI notes from Run three. Three notes from one Stack have also been reported from one Stack that were I-10 notes. No notes have been reported from the short Run four (80,000 sheets). Based on the notes observed, the L/* Block is 10.526 percent SOI.

• F/* - printed in DC during September 2008. The second Run of F/* notes (03200001-06400000) is the only Run printed in DC. The other Runs of F/* notes (Runs 1 and 3) were printed in FW and have been observed as I-10 notes. Four of the 10 Stacks from Run two have been observed as SOI notes giving the F/* from DC a 40 percent SOI percentage.

• K/* - printed in FW during November 2009. There was one full Run of 100,000 sheets printed during November 2009. Eight of the 10 Stacks have been observed as SOI notes giving the K/* an 80 percent SOI percentage.



Conclusion

This report has been limited to identifying and analyzing the SOI notes by Block, which is the most common way a collector will collect the SOI notes. However, there are some collectors who may want to collect the SOI notes by Block and Run. This method of collecting, while rewarding to the successful collector, will be a challenge. A more common method of collecting would be to collect an I-10 note and an SOI note from each Block. This method in itself will be a challenge due to the limited number of SOI notes reported for some Blocks. The good news is that Series 2006 notes can still be found in circulation and offers the collector something to look for in change.



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