Heidelberg Speedmaster XL 106s Drive Folding Carton Sales

J.S. McCarthy Packaging + Print, one of the oldest and largest packaging and commercial printers in New England, recently installed a Speedmaster XL 106 from HEIDELBERG. The new XL 106, with running speeds of 21,000 sph, is among the fastest offset presses for folding carton production in the world. Since its installation, the press has boosted J.S. McCarthy’s capacity significantly, enabling the company to grow its burgeoning folding carton business by an additional 50%.

250,000,000 Impressions and Counting

J.S. McCarthy, based in Augusta, ME, began as a commercial printer in 1947 and expanded into packaging almost twenty years ago. The company has spent the last seven years making strategic infrastructure and equipment investments to bolster its strength in the packaging segment, including the purchase of a Speedmaster XL 106-4+LYY-P+4+L in 2018. Today, folding carton production accounts for nearly 80% of the company’s business – primarily for the food, pharmaceutical, and cosmetic markets.

Since installing its XL 106 in 2018, J.S. McCarthy has increased sales upwards of 20%. This press replaced two older presses from other manufacturers and boosted the plant’s productivity by 50% upon installation. While initially purchased to print both commercial and packaging jobs, the perfecting press now almost exclusively runs folding cartons at its top speed of 18,000 sheets per hour – acquiring nearly 250,000,000 impressions. “The XL 106 delivers reliable, proven productivity day in and day out,” said President Jon Tardiff. “The impression count for good sheets to the floor is significantly better than what we’ve experienced with other manufacturers’ equipment.”

Left to right: Jason Baird and Jordan Wooldridge, press operators.

Folding Carton Production at 21,000 SPH

In response to its rapid growth in packaging, J.S. McCarthy recently added 12,000 square feet of new office space and a Speedmaster XL 106-8+L, its first press designed exclusively for folding carton production. Its newest XL 106, installed earlier this year, is equipped with UV curing and Prinect Inpress Control 3 and replaces an older perfecting press from a different manufacturer. With speeds of 21,000 sheets per hour, the XL 106 is HEIDELBERG’s fastest press to date and will help the company keep up with its anticipated sales revenue growth.

The XL 106-8+L has cut turnaround times in half since live sheets began in February, with J.S. McCarthy now completing high-volume folding carton jobs in as little as seven days. Its team regularly produces 1 to 1.5 million weekly impressions in a three-shift operation. According to Tardiff, “Our capacity has expanded significantly. Previously, it was difficult getting jobs through the plant fast enough, but we’re processing work so efficiently now we believe we can increase our business by another 50%.”

To achieve higher speeds and net output, HEIDELBERG optimized over 200 components throughout the XL 106, from feeder to delivery. The improved components and advanced Speedmaster technology, like new intelligent User Experience (UX), autonomous Push-to-Stop technology, and AutoPlate Pro help maximize efficiency and maintain maximum output levels throughout high-speed production. Additionally, the press is equipped with logistics in the feeder and delivery, which Tardiff says is “essential to maintain productivity due to the sheer amount of material that’s being produced on the press.”

J.S. McCarthy’s XL 106 also includes Prinect Inpress Control 3, HEIDELBERG’s industry-leading inline spectrophotometer that measures and corrects color, even at 21,000 sheets per hour. With Inpress Control, J.S. McCarthy’s team can monitor color directly from the Wallscreen at the press. Additionally, quality reports can be easily exported from Prinect and shared with customers to demonstrate consistency throughout the run. “Our superior color control has attracted the attention of several national brands,” said Tardiff. Inpress Control also significantly cuts down on the makeready process with press runs consistently producing less than 1% waste.

Higher efficiency production and waste reduction are crucial elements of J.S. McCarthy’s overall sustainability goals. “In transitioning from commercial print to folding carton packaging, we’ve invested significantly in our facility, equipment, and team, while prioritizing environmental responsibility,” said Tardiff. The company opted for a carbon-neutral press, which means CO2 emissions that are generated during press production are compensated for by purchasing climate protection certificates (Gold Standard).

After many years of running presses from other manufacturers, Tardiff continues to be amazed by HEIDELBERG’s “proven” productivity. Previously, the company ran three presses with ten press crews and still struggled to get jobs printed and completed in an efficient manner. Today, J.S. McCarthy runs only its two XL 106s with four press crews and has ample capacity for future growth. “Both of our XL 106s have exceeded my expectations in what they can produce,” said Tardiff. “For me, it’s all about good sheets to the floor and these presses perform exactly how HEIDELBERG says they will.”

Source: Heidelberg

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