In the packaging printing landscape, there is now only one key word: productivity. But not productivity for its own sake, rather, productivity that is sustainable, automated, and capable of responding to the growing complexity of the folding carton market. It is in this context that Heidelberg’s new Boardmaster comes into play: a machine that marks a paradigm shift in industrial cartonboard production. We discuss it in the article and in the videointerview with Mauro Antonini and Luca Losi of Heidelberg Italia
Officially unveiled at Interpack 2023 and showcased during several events at Heidelberg’s new “Home of Print,” inaugurated last year in Wiesloch, Germany, on the occasion of the German manufacturer’s 175th anniversary, the Boardmaster redefines the production paradigm for cartonboard by bringing web flexographic printing to levels of automation, productivity, and integration previously associated with other industrial sectors. This is not simply a new machine, but a complete production concept: from reel to finished die-cut product in one continuous, highly automated, and configurable workflow.
Designed entirely from scratch at Heidelberg’s competence center in Weiden, Bavaria, the Boardmaster was developed to address some of the key challenges packaging producers face today: cost pressure, shortage of skilled labor, increasing sustainability demands, and higher production volumes.
A new concept of industrial flexo printing
Unlike traditional sheetfed offset presses, the Boardmaster is a web-fed rotary flexographic press designed for high-volume folding carton production. Its approach is based on one fundamental principle: eliminating unproductive downtime. With a printing speed of up to 600 meters per minute, optionally reaching 800 meters per minute, the Boardmaster can double productivity compared to comparable printing systems.
The machine is designed to guarantee operational uptime of up to 90%, thanks to an innovative concept that enables “on-the-fly” job changes without interrupting production. Each printing unit includes two stations: while one is printing, the other is being prepared for the next job, eliminating press downtime. This approach enables virtually continuous production, minimizing waste, less than 10 meters per job change, and significantly improving overall efficiency.
The Boardmaster takes advantage of the best of state-of-the-art flexographic printing, with resolutions up to 70 lines per centimeter (5080 dpi) and a minimum dot size of 50 microns, with optimized anilox transfer volume management. The Boardmaster is available in four printing widths ranging from 850 to 1,650 mm.
Another distinctive element of the Boardmaster is its high level of automation, reflecting Heidelberg’s broader strategy toward autonomous printing. The system integrates advanced technologies such as the Intellimatch scanner, which analyzes printing plates and automatically adjusts the printing units, ensuring consistent quality and drastically reducing setup times. This high level of automation also allows operation with reduced staffing levels, addressing one of the sector’s most pressing challenges: the difficulty of finding highly qualified personnel.
Flexibility and sustainability: responding to new packaging demands
The Boardmaster is designed to handle a wide range of substrates with grammages between 70 and 800 g/m², covering most folding carton applications, particularly for food, beverage, and FMCG packaging. It can be configured with up to 10 colors, while the use of water-based inks and high energy efficiency further enhance the sustainability of the process, supporting material recyclability and reducing environmental impact.
From a configuration standpoint, the machine can be integrated into different production workflows, reel-to-reel, reel-to-sheet, or directly to die-cutting, and can include inline processes such as lamination, UV coating, embossing, screen printing, and digital printing. The final sheeting system also offers high production flexibility, capable of producing up to 25,500 sheets per hour.
A new positioning for industrial packaging
With the Boardmaster, HEIDELBERG is not simply introducing a new machine, but proposing a new production model for industrial packaging. Its modular architecture allows configurations to be tailored to specific customer requirements and upgraded over time, providing investment security in a constantly evolving market environment. This solution also fits into a rapidly growing segment, driven by the progressive replacement of plastic with fiber-based materials and the increasing global demand for sustainable packaging.
In this scenario, the Boardmaster positions itself as a concrete response to converters seeking to increase competitiveness through automation, efficiency, and a new concept of industrial production.
Face to face with Luca Losi, Business Driver Sheetfed Offset & Web Folding Carton
What are, in summary, the key elements that make the Boardmaster particularly competitive compared to traditional offset technologies?
“One of the most significant aspects is certainly the use of paper in reels, which is less expensive than pre-cut sheets. Added to this are productivity levels comparable to three large-format offset presses, along with more efficient waste and maintenance management. Overall, the Boardmaster enables significantly higher production volumes with lower operating costs, greatly improving industrial efficiency”.
The Italian market is largely made up of small and medium-sized converters. Can the Boardmaster also represent an opportunity for these companies?
“It is a machine designed for production environments with significant volumes, but the continuous job change system also makes it attractive for companies handling diversified orders. Therefore, it is not a solution reserved exclusively for large groups, but can also be considered by structured companies looking to increase production capacity and prepare for future growth”.
Under what conditions does investing in this press become strategic?
“The Boardmaster becomes a strategic choice when the goal is to significantly increase production capacity and reduce unit costs, while maintaining high levels of automation and reliability. It is a technology designed for companies that want to make a leap forward in terms of efficiency and industrial positioning”.
What feedback are you receiving, and what plans do you have to introduce the Boardmaster to Italian companies?
“The feedback from the Italian market has been positive. Several companies are looking at the Boardmaster with great interest, particularly because of the strong trend toward shifting from plastic to paper. Every year we organize the ‘Packaging Day’ at the Home of Print in Wiesloch, where we present a global overview of integrated solutions for our customers’ production departments. During this event, we also showcase the Boardmaster, which is always available for dedicated tests and demos, regardless of institutional events. Finally, our sales force is always available to introduce the Boardmaster, as well as all our products, throughout the entire national territory”.
