Just over one year after installing its second Speedmaster XL 106, J.S. McCarthy Packaging + Print, one of the oldest and largest packaging and commercial printers in New England, set a new world record for folding carton production – printing 429,246 net sellable sheets (431,451 gross sheets) in 24 hours.
J.S. McCarthy’s team achieved this milestone running 23.6 pt. CKBTM by Stora Enso at 21,000 sheets per hour across two twelve-hour shifts on its Speedmaster XL 106-8+L from HEIDELBERG. In total, J.S. McCarthy’s team printed a remarkable 1,165,636 net sheets over the course of sixty-seven hours. “We’re always setting new goals and striving to do things better, faster, and more efficiently,” said Jon Tardiff, President of J.S. McCarthy.
“Equipped with one of the fastest and most automated presses in the world, we had everything in place to make this world record possible: the right technology, the right people, and the right mix of work.” 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 intelligent User Experience (UX) featuring AI-powered press assistance systems, autonomous Push-to-Stop technology, and AutoPlate Pro help maximize efficiency and maintain maximum output levels throughout high-speed production. J.S. McCarthy’s record-setting production involved four different press forms, requiring multiple plate changes, including an additional ten to ensure print quality and dot integrity over the long run, due to plate wear.
Thanks to the press’s advanced Push-to-Stop system and Prinect Inpress Control 3 color control technology, changeover and make-ready processes were fully automated – allowing the team to return to full production within minutes. Prinect Inpress Control also helped minimize make-ready and waste sheets to 7,012 (0.60%) over the entire run of 1,172,648 sheets.
“When you’re running at these speeds, the press technology has to make it easy for operators to sustain that pace while still maintaining quality, and this press does exactly that. The XL 106 consistently exceeds our expectations day in and day out,” said Tardiff. Additionally, the press’s logistics systems, which manage the automated loading of the feeder and removal of printed pallets at delivery, were key to ensuring uninterrupted, non-stop production.
The full run, which surpassed a million sheets, required approximately 600 pallets – with skid changes occurring every 5.5 to 6 minutes. Due to the thickness of the board, each pallet could only hold 2,000 sheets. Tardiff explained that without these advanced logistics capabilities, the record would not have been attainable. To assist with moving pallets to and from press, each production shift was equipped with a materials handler in addition to an operator and press apprentice.
“This record is not just about having the best equipment – it’s about having the best people behind it,” said Tardiff. “We’re beyond proud of our team for pulling off this incredible achievement, and we can’t thank them enough for their relentless hard work and dedication.” Additionally, he credited his in–house sheeting team, who did “an excellent job delivering nice, flat loads to the press, which made a huge impact on our performance.”
Over the past twelve months, HEIDELBERG customers worldwide have set multiple new world records across all industry segments. Clarence Penge, EVP of Product Management for Heidelberg USA, commented, “These accomplishments are a testament to the sheer power of the Speedmaster XL 106.
Congratulations to the team at J.S. McCarthy for achieving this exceptionally challenging feat with thick board stock in folding carton production.” Tardiff concluded, “I consider HEIDELBERG and Stora Enso true partners in our success. Without their support, achievements like this wouldn’t be possible.”
