What does the machine do?
The Boardmaster is a flexo printing system for high-volume folding carton applications and increases productivity and efficiency tremendously. At the same token it is possible to reduce waste drastically.

Which are the different models?
The Boardmaster offers some variations and options. It is available in four different web widths — 850-mm, 1,000-mm, 1,400-mm and 1,650-mm. It is available in two speed classes depending on the customer’s need — 350-m/min and 600-m/min. As a non-standard option, 800-mtr/min speed is also available. The printers can choose the level of automation — from an operator-controlled machine up to a fully autonomous printing press with non-stop operation.

How do these models differ from each other?
Each print deck consists of two print units of which one is always printing, the second one is prepared for the next job. They can be chosen as non-stop print decks where the machine can make job changes without being stopped; even the substrate changes can be done without being stopped. This means the run length of a job is not important anymore as the machine can continuously run. The change from one job to the other creates minimal waste (maximum 10 to 15 metres) even at full speed. 

The other version of the Broadmaster has a double print deck and has also two print units which print different inks simultaneously...

Of course, there are hybrid lines where both versions of print decks can be combined, depending on the needs and ideal configurations of a printer. Each print deck could be equipped easily with back-side printing. For high investment security, the machine could be equipped at any stage of its lifetime with additional converting options, such as cold foiling, lamination, embossing, etc. The machine can run roll-to-roll, roll-to-cutter (flatbed or rotary) and roll-to-sheeter. Ideally, it is from the roll to the finished blank or stack of blanks.

When was the printing press launched?
At Interpack 2023 in Düsseldorf, Germany.

What was the thought process when the press was conceived?
The Boardmaster was developed completely from scratch at the Heidelberg competence centre for high-volume flexo folding carton printing at the company’s Weiden site in Bavaria, Germany. The development work was carried out in close collaboration with international packaging customers and factored in their key challenges – cost pressure, the skills shortage, and the need to optimise productivity and sustainability.

What is/are the target market(s)?
The Boardmaster is especially suited to the food and beverage sector’s folding carton applications, which are becoming increasingly popular worldwide due to a growing global demand for packaged products.

What is/are the target market(s)?
The Boardmaster is especially suited to the food and beverage sector’s folding carton applications, which are becoming increasingly popular worldwide due to a growing global demand for packaged products.

What kind of substrates can it handle?
Substrates with grammage of between 70 and 800-gram per square metre can be processed in the machine.

How fast is it?
The printing speed is up to 600-m/min, which corresponds to around 38,000 printed sheets in format six (sheet width 148-cm) per hour.

What is the USP of the press?
The Boardmaster offers machine availability of up to 90% and a maximum printing speed of 600-mtr/min. It delivers double productivity and thus dramatically reduces the total cost of ownership in industrial packaging production.

How is conserving resources a key focal point with the kit?
The Intellimatch pre-press scanner safeguards printing quality, also ensuring the print decks are adjusted correctly and fully automatically. The machine delivers less than 10-mtr of paper waste per job change. It offers far higher energy efficiency as a function of productivity than offset printing. Plus, using water-based inks improves the material’s recyclability.

It’s a high investment kit?
High investment security is ensured, as the system’s modular design means users are able to grow in line with market requirements and adapt the relevant machine configuration to changed market conditions.

How easy is it to use?
Given the fact that in many regions of the world, there are labour and skill shortages, it has always been a focus that the machine is easy to handle and offers as much automation as a printer wants to have.

What training and support are on offer?
Heidelberg provides training during start-up in a modular way: basic flexo training, maintenance training, as well as in-depth operational and process training. The training courses can be configured according to the knowhow level of the personnel at the printer. We also do organisational consultancy with the target of a highly efficient workflow around the machine.

How much does it cost?
Prices are strictly dependent on the configuration. The range is roughly between a low single-digit to a double-digit million euros.

Contact details: 
Matthias Boog, managing director, Heidelberg Web Carton Converting GmbH
Email: matthias.boog@heidelberg.com
Phone: +49 (961) 39 39 700