Colbert Packaging Installs Heidelberg Speedmaster XL 106 Press

 Colbert Packaging, a leading manufacturer of folding cartons, rigid paper boxes and paperboard specialty products, announced that a brand new Heidelberg Speedmaster XL 106 printing press is now fully operational in its Elkhart, IN, manufacturing facility. The 40″ offset press can print six-color processes and coat paperboard in a single pass—using both conventional and ultraviolet inks and coatings.

The Heidelberg Speedmaster XL 106 is fast. Not only was it built to run at speeds of up to 18,000 sph, but Colbert’s new press also includes some special features that increase production efficiency. The full logistic feeder package is one such feature; with it, the press quickly and easily performs load changeovers and enables continuous feeding. Automatic plate hangers also provide for rapid plate hanging; all six printing plates are simultaneously hung in only 90 seconds.

“We wanted to achieve high efficiency, though certainly not at the expense of high quality,” said Bill Snyder, vice president of operations for Colbert Packaging. The Heidelberg has built-in quality assurance features, including an in-press color control scanner, which automatically scans every 16 sheets and feeds color values to press operators as the job is running. “This new press meets our high standards, and our people are very excited about its capabilities and speed,” he added.

Colbert started training its people on the new press in early February, when four employees spent a week at Heidelberg USA in Kennesaw, GA. The training—which was conducted by a Heidelberg Master Demonstrator—included hands-on experience with machine startup and shutdown, job setup and high-speed production, seamlessly switching between ultraviolet and conventional inks, proper cleaning and maintenance, etc. In recent weeks, the newly installed Heidelberg press has undergone significant testing, and additional training has been conducted onsite in Colbert’s Elkhart, IN, facility.

The Heidelberg Speedmaster XL 106 runs at speeds of up to 18,000 sph.

“This new press will have a major impact on our entire operation,” said Jim Hamilton, president of Colbert Packaging. “In addition to quality and efficiency improvements resulting from the upgraded technology, the press will also provide additional capacity and expanded capabilities.”

The Heidelberg Speedmaster XL 106 offset press joins an extensive repertoire of equipment used to produce folding cartons, rigid setup boxes and paperboard specialty products, including formed paper trays, in Colbert’s 109,000-square-foot manufacturing plant in Elkhart, IN.

Walstead expands with Spanish buy

Wyndeham Group owner Walstead has expanded onto the continent – and into gravure printing – with the acquisition of Be Printers’ £100m turnover Spanish operations from Bertelsmann. Scanlon: expecting further consolidation opportunities Walstead Investments has bought the operations of gravure printer Eurohueco, based in Barcelona, and Madrid web offset printer Rotocobrhi, through affiliate company Walstead Capital.

Together, the two companies employ 567 staff and had sales last year of €137m (£101.4m). The terms of the deal were not disclosed. Walstead Capital is owned by the same four directors as Walstead Investments: Mark Scanlon, Richard Fookes, Stephen Hargrave and Paul Utting.

Scanlon, who is chairman of both companies, told PrintWeek the acquired companies were well invested, profitable and cash-generative.
“This, undoubtedly, boosts our profile in the European market. Many competitors in the Spanish market are weak, so we expect there will be consolidation opportunities,” he said.

“Spain is a recovering economy – its print market is experiencing the same issues and challenges that we’ve had to tackle since 2008. So, we’re going in to this with our eyes wide open and under no illusions what to expect and how to remain successful.”

Be Printers chief executive Bertram Stausberg said it had been “a key requisite” that the buyer would support and invest in the operations. Be Printers, which also owns Prinovis, sold off its Italian print division last October as part of the same strategic review and has now exited the Italian and Spanish print markets.

“This concludes our portfolio sale process,” Stausberg said. “We will now concentrate fully on developing our Prinovis printing businesses in Germany and the UK as well as our book and packaging printing businesses in the US.”

Rotocobrhi employs 314 staff at its 29,000sqm Madrid facility. It runs two 80pp web offset presses, three 48pp, and three 16pp webs. Eurohueco is located in a purpose-built 22,000sqm factory near Barcelona. It employs 235 and runs two KBA TR7 and two Cerutti RS35 gravure presses. The plants produce magazines, flyers, catalogues and supplements.

On the move into gravure, Scanlon said: “Eurohueco manufactures mainly press finished or stitched products for the retail and catalogue markets where volumes are more stable than for publications. Over 50% of its output is exported, most of it to France.

“Geographically and strategically it’s in a great spot. We’re not buying into gravure as a technology. Instead, we’ve seen this as an opportunity to acquire a large, blue-chip client base that requires long-run printed products and with few competitors in the region. If, in the future, our clients’ needs can be satisfied with an alternative, more cost-effective manufacturing process, then we will adapt our offering by investing in it.”
Mauro Cosani, the chief executive of the Spanish division, remains in his role.

Scanlon added: “Despite being overseas, we have sufficient management resources here [in the UK] to manage this group. We have an experienced team with excellent skill sets and there is a very well-established executive team in Spain.”
Wyndeham Group chief executive Utting will address the workforce at both plants in Spanish.

Cenveo Installs KBA Rapida 106 Press

“Our goal was to produce an intricate, multi-dimensional box that displayed all of the value added features of the KBA press, as well as our creative structural design and production capabilities,” said Emily Allen, director of marketing and XP sales for Cenveo’s packaging division. “The intent was to have the promotional piece completed in time for the Tobacco Plus Convenience Expo, which targets the tobacco and vapor markets, held in late January 2015 in Las Vegas. Due to non-disclosure agreements in place with many of our customers in this market, we wanted to have a Cenveo branded product to hand out and demonstrate our innovative packaging capabilities relative to this market. At the end of the two-day show, the promo piece was considered a huge success. We gained an enormous amount of traction as a result, which led to new business and exposure for Cenveo. Our sales group continues to promote this piece to customers, and we incessantly use it as an internal tool to promote the KBA press.”

Cenveo’s strengths, all of these internal components were secured through various divisions of the company. The Labels division printed and produced the playing cards, while their Strategic Sourcing division supplied the additional products.

Cenveo installed the Rapida 106 with the goal to differentiate them from the competitive landscape. Being the only printer in the Southeast with this unique set of printing applications, it allows them to quickly respond to print markets. Special features on the press include an increased number of available printing units, an in-line cold foil system, dual UV coating capabilities, UV drying, VariDry Blue infrared/hot air drying system, a large wall screen at the press console, complete automation including KBA’s unique ErgoTronic system, a KBA board package, and a raised platform. Another key feature of Cenveo’s press is the KBA QualiTronic color-control and inspection system, a camera-based in-line sheet-inspection system that scans each sheet and compares it with a reference sheet for copy and color validation. This feature was particularly valuable when the firm produced the promotional piece for the tobacco and vapor market.

“Our KBA Rapida 106 press provides our clients unique solutions for their packaging needs,” remarked D.J. Cabler, pressroom manager at Cenveo’s Jacksonville, FL, facility. “This particular promo piece speaks to our talent as a print and folding carton manufacturer. It utilizes the capabilities of our new press with cold foil and specialty coatings, and KBA’s unique SIS for perfect register for multiple passes. We were able to transform standard SBS paperboard to look like a real wooden humidor box.”

Cabler says that even after operating the Rapida 106 press for 18 months, press operators and crew are still learning new processes and testing new substrates with a high dedication to R&D efforts. At a minimum, the press is operational 24 hours a day five to six days per week.

The combination of all the unique print and coating elements elevated the piece to a higher perceived value, which is exactly the message we’re promoting to our client base for their brand packaging” relayed Allen.

Hunter Johnston, senior vice president of sales and operations for Cenveo’s Packaging division, also noted, “We want to be the first company in the market to introduce new offerings and services to our customers. We have demonstrated success in providing unique solutions that support our customers’ brand vision and profitability, not only with value added print applications, but with functional packaging designs that efficiently run through our equipment and serve as market leading designs in any retail environment. As we continue to push the boundaries through extensive R&D efforts, we further secure our place in the market as our customers’ first choice for any packaging and print related needs. Cenveo remains focused on making our customers successful by optimizing and empowering their brands.”