{"id":97041,"date":"2026-06-18T11:00:04","date_gmt":"2026-06-18T09:00:04","guid":{"rendered":"https:\/\/www.converter.it\/?p=97041"},"modified":"2026-06-03T09:01:35","modified_gmt":"2026-06-03T07:01:35","slug":"heidelberg-boardmaster-the-new-frontier-of-productivity-in-flexo-printing-for-folding-cartons","status":"publish","type":"post","link":"https:\/\/www.converter.it\/en\/heidelberg-boardmaster-the-new-frontier-of-productivity-in-flexo-printing-for-folding-cartons\/","title":{"rendered":"Heidelberg Boardmaster: the new frontier of productivity in flexo printing for folding cartons"},"content":{"rendered":"<p><em>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 <a href=\"https:\/\/www.converter.it\/en\/heidelberg-planning-to-extend-boardmaster-applications-for-growing-segment-of-flexible-paper\/\" target=\"_blank\" rel=\"noopener\">Heidelberg\u2019s new Boardmaster<\/a> 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<\/em><\/p>\n<p><iframe loading=\"lazy\" title=\"HEIDELBERG Boardmaster: la nuova frontiera nella stampa flexo di astucci pieghevoli_ENG SUB\" width=\"696\" height=\"392\" src=\"https:\/\/www.youtube.com\/embed\/ltlXqR1escE?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<p>Officially unveiled at Interpack 2023 and showcased during several events at Heidelberg\u2019s new <a href=\"https:\/\/www.converter.it\/en\/heidelberg-the-new-home-of-print-inaugurated-and-the-cartonmaster-cx-145-presented-in-partnership-with-manroland\/\" target=\"_blank\" rel=\"noopener\">\u201cHome of Print,\u201d<\/a> inaugurated last year in Wiesloch, Germany, on the occasion of the German manufacturer\u2019s 175th anniversary, the <strong>Boardmaster<\/strong> redefines the production paradigm for <strong>cartonboard<\/strong> by bringing <strong>web flexographic printing<\/strong> 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.<br \/>\nDesigned entirely from scratch at Heidelberg\u2019s 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.<\/p>\n<p><strong>A new concept of industrial flexo printing<br \/>\n<\/strong>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.<br \/>\nThe machine is designed to guarantee operational uptime of up to 90%, thanks to an innovative concept that enables \u201con-the-fly\u201d 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.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-97037 size-full\" src=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360.jpeg\" alt=\"\" width=\"567\" height=\"425\" srcset=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360.jpeg 567w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360-300x225.jpeg 300w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360-560x420.jpeg 560w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360-80x60.jpeg 80w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-boardmaster_4360-265x198.jpeg 265w\" sizes=\"auto, (max-width: 567px) 100vw, 567px\" \/><\/p>\n<p>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.<br \/>\nAnother distinctive element of the Boardmaster is its high level of automation, reflecting Heidelberg\u2019s 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\u2019s most pressing challenges: the difficulty of finding highly qualified personnel.<\/p>\n<p><strong><img loading=\"lazy\" decoding=\"async\" class=\"alignright size-medium wp-image-97033\" src=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-cambio-manica-boardmaster-225x300.jpeg\" alt=\"\" width=\"225\" height=\"300\" srcset=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-cambio-manica-boardmaster-225x300.jpeg 225w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-cambio-manica-boardmaster-315x420.jpeg 315w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Heidelberg-cambio-manica-boardmaster.jpeg 319w\" sizes=\"auto, (max-width: 225px) 100vw, 225px\" \/>Flexibility and sustainability: responding to new packaging demands<br \/>\n<\/strong>The Boardmaster is designed to handle a wide range of substrates with grammages between 70 and 800 g\/m\u00b2, 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.<br \/>\nFrom 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.<\/p>\n<p><strong>A new positioning for industrial packaging<br \/>\n<\/strong>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.<br \/>\nIn 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.<\/p>\n<p><strong>Face to face with Luca Losi, Business Driver Sheetfed Offset &amp; Web Folding Carton<\/strong><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-97031\" src=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Luca-Losi-Heidelberg.jpg\" alt=\"\" width=\"567\" height=\"255\" srcset=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Luca-Losi-Heidelberg.jpg 567w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/Luca-Losi-Heidelberg-300x135.jpg 300w\" sizes=\"auto, (max-width: 567px) 100vw, 567px\" \/><\/p>\n<p><strong><em>What are, in summary, the key elements that make the Boardmaster particularly competitive compared to traditional offset technologies?<br \/>\n<\/em><\/strong>\u201cOne 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\u201d.<\/p>\n<p><strong><em>The Italian market is largely made up of small and medium-sized converters. Can the Boardmaster also represent an opportunity for these companies?<br \/>\n<\/em><\/strong>\u201cIt 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\u201d.<\/p>\n<p><strong><em>Under what conditions does investing in this press become strategic?<br \/>\n<\/em><\/strong>\u201cThe 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\u201d.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-97035\" src=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/HEIDELBERG_Boardmaster_3.jpg\" alt=\"\" width=\"567\" height=\"378\" srcset=\"https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/HEIDELBERG_Boardmaster_3.jpg 567w, https:\/\/www.converter.it\/wp-content\/uploads\/2026\/05\/HEIDELBERG_Boardmaster_3-300x200.jpg 300w\" sizes=\"auto, (max-width: 567px) 100vw, 567px\" \/><\/p>\n<p><strong><em>What feedback are you receiving, and what plans do you have to introduce the Boardmaster to Italian companies?<br \/>\n<\/em><\/strong>\u201cThe 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 \u2018Packaging Day\u2019 at the Home of Print in Wiesloch, where we present a global overview of integrated solutions for our customers\u2019 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\u201d.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>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\u2019s new Boardmaster comes into play: a machine that marks [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":97039,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[456,480,468],"tags":[],"class_list":["post-97041","post","type-post","status-publish","format-standard","has-post-thumbnail","category-converter-cartotecnica","category-flexography-technologies-converter-cartotecnica","category-printing-and-prepress-technologies"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Heidelberg Boardmaster: flexo printing for folding cartons<\/title>\n<meta name=\"description\" content=\"HEIDELBERG Boardmaster is a machine that marks a paradigm shift in the industrial production of folding carton\" \/>\n<meta name=\"robots\" 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