Following its premiere at Interpack 2023, HEIDELBERG recently presented the Boardmaster to international experts in production operation. The new web-fed flexographic printing press is characterized by a doubling of productivity compared to previous comparable systems. It is the answer of HEIDELBERG to the attractive packaging market, in which high-volume flexographic printing plays an important role.
Packaging printing is an important strategic growth area for Heidelberger Druckmaschinen AG (HEIDELBERG). HEIDELBERG already generates more than 50 percent of its sales in the packaging printing segment. As a result, the company is continuing to invest in the development of sheetfed offset technology, which has already proven itself in this segment, the promising digital printing systems of its Swiss subsidiary Gallus for digital label printing and, with the new Boardmaster, in flexographic printing for new market segments such as high-volume folding carton production.
The global market for folding cartons is growing. The increase in folding carton production is estimated to rise from 68 billion euros today to 76 billion euros by 2027. This corresponds to growth of 2.3 percent per year. In the area of high-volume folding carton production, flexographic printing will benefit in particular. In relation to the overall market, the proportion of packaging produced using flexographic printing is expected to rise from 13.7% (2010) to 15.2% (2027). HEIDELBERG’s forecasts are based on market studies by the PIRA, RISI and S&P Global Insights institutes.
HEIDELBERG has therefore developed the Boardmaster for the attractive flexographic printing segment. It is produced at Heidelberg Web Carton Converting GmbH in Weiden, Germany. The new flexographic web press made its debut at Interpack in Düsseldorf in May 2023. With resounding success, as Matthias Boog, Managing Director at Heidelberg Web Carton Converting GmbH , says. “The first systems are already producing in the USA. We have further orders from Asia and Africa, and we are receiving inquiries from all regions of the world.” Print shops that previously produced packaging for food and beverages in large-format offset are also showing a strong interest in the Boardmaster, says Matthias Boog.
The development of the Boardmaster was driven by four aspects that currently pose a particular challenge to packaging printers: Productivity or cost pressure, quality and operational reliability, sustainability and a high level of investment security. HEIDELBERG derived these aspects from an in-depth needs analysis together with 25 selected packaging printers.
Efficiency increases productivity and reduces costs
The Boardmaster is designed for the highest possible Overall Equipment Efficiency (OEE) in non-stop operation with flying job changes. The availability of the printing press thus reaches up to 90 percent, with a maximum printing speed of 600 meters per minute. Compared to previous comparable systems with an availability of 45 percent, this corresponds to a doubling of productivity. HEIDELBERG has also reduced maintenance costs on the Boardmaster by 50 percent compared to systems with other printing processes.
Quality and security make flexographic printing increasingly attractive for folding carton production
A high degree of automation and simple operation make it possible to produce on the Boardmaster with low staffing levels and a high level of operational reliability. In this way, HEIDELBERG also counteracts the increasing shortage of professionally qualified operating personnel. The system delivers print results that meet a globally recognized high quality standard. This is where the Intellimatch quality assurance system comes into play. Cameras analyze the flexographic printing plates down to the smallest detail. Data is evaluated using algorithms supported by artificial intelligence. All setting parameters recorded by Intellimatch are transmitted to the relevant Boardmaster printing unit via a matrix code identifier. The external quality check reduces the set-up effort in the machine to zero. The quality check also prevents faulty printing plates from being used in the machine.
Sustainability in folding carton production increasingly decisive for competition
In general, the Boardmaster supports the global trend away from plastic packaging towards fiber-based and therefore more sustainable folding cartons. When developing the system, HEIDELBERG also took care to ensure that packaging producers can also produce particularly sustainably. Thanks to the flying job changeover, the system works with comparatively little waste. When producing at a maximum output of 600 meters per minute, the proportion of unprinted material is less than ten meters during a job change.
The Boardmaster also works with water-based printing inks, with the web passing through a hot-air dryer after each printing unit (UV-curing printing inks or a hybrid configuration with hot-air drying and UV curing is available as an option). Water-based printing inks are good for the indoor and working climate and, due to their degradation properties, for the environment. They are also free from harmful substances and can be used without hesitation for printing food packaging.
Modularity offers investment security
The Boardmaster is based on a modular concept and can be configured exactly according to customer requirements, with a largely free choice in terms of the number of printing units. One or two printing units are possible per printing unit (flying job change). Modules for die-cutting, laminating or cold foil application can be integrated as an option. This modularity offers the market maximum investment security and is also possible at any time during the service life of the system.
Further market potential for fiber-based packaging
The Boardmaster currently covers the segments of folding carton printing and coated cardboard packaging for liquid products (liquid packaging). HEIDELBERG sees further application potential for the new web-fed flexo press in the corrugated board printing segment, for example display stands for promotional items in supermarkets, as well as in flexible paper packaging, e.g. outer packaging for chocolate, pasta, etc.. The latter are particularly interesting in terms of substituting plastics with more sustainable, fiber-based materials. Nicola Kopp-Rostek also emphasizes the aspect of sustainability. She manages the DFTA Flexodruck Fachverband e.V. in Stuttgart, Germany, and considers the future prospects for the flexographic printing process to be very good. “A major strength of flexographic printing is the environmentally friendly use of resources. Thanks in particular to a comparatively very thin ink application, this printing process supports the efforts of packaging printers to minimize their impact on the environment,” she says.
Successful market entry: Boardmaster customer event leads to further concrete sales talks
Following its premiere at Interpack, the Boardmaster was presented to international experts in production operation at the Heidelberg Web Carton Converting GmbH site in Weiden in November. Around 100 customers from Central and Southern Europe, North America and Asia came to see the system’s capabilities for themselves. The machine produced three different jobs from reel to reel, switching between two jobs on the fly at full production speed.
“The demonstrations went to our complete satisfaction,” says Christian Steinmaßl, Head of the Packaging Segment at HEIDELBERG, referring to “a number of specific inquiries with definition of the configuration”. Several customers were specifically interested in test runs and wanted to send their substrate and printing plates to Weiden. The Boardmaster aroused enthusiasm and encouraged visitors to explore what is possible with such a printing system and how it can be integrated into existing production structures. “HEIDELBERG has really hit a nerve in the market with the Boardmaster. The market launch is proving successful and customer demand continues to develop very positively,” concludes Steinmaßl. “This underlines the success of the HEIDELBERG strategy of being able to grow in new market segments in its core printing business.”
Image 1 (graphic): The Boardmaster from HEIDELBERG: More availability, twice the productivity.
Photo 2: Around 100 customers and interested parties from Central and Southern Europe, North America and Asia came to the Heidelberg Web Carton Converting GmbH site in Weiden, Germany, in November to see the performance of the Boardmaster.
Image 3: They draw a positive conclusion from the customer event (from left): Christian Steinmaßl, Head of the Packaging Segment at HEIDELBERG, Werner Schwab, Head of Product Management at Heidelberg Web Carton Converting GmbH and Matthias Boog, Managing Director of Heidelberg Web Carton Converting GmbH.
Image 4: Full throttle: The maximum printing speed of the Boardmaster is 600 meters per minute.
Image 5: A high degree of automation and simple operation make it possible to produce on the Boardmaster with low staffing levels and a high level of operational reliability. An operator changes the impression cylinder.
alte Mosterei in Münsingen
Image 6: Nicola Kopp-Rostek, Managing Director of DFTA Flexodruck Fachverband e.V., particularly emphasizes the sustainability aspect of the Boardmaster: “Thanks to a comparatively very thin ink application, this flexographic printing press supports the efforts of packaging printers to minimize their environmental impact.”
