With a 180-year history and now under the fourth generation of family ownership and management, Zumbiel’s expertise in printed carton production is extensive.  The company operates a 500,000 sq ft (46,450 sqm) facility in Hebron, KY, employing 380 staff members, and the facility has become a hub of excellence with its digital production line nearing the goal of achieving an 85% overall equipment efficiency (OEE) target.

Traditionally, Zumbiel’s carton production relied on sheet-fed offset and wide-web flexo presses. However, in response to changing market demand, such as declining run lengths and an increasing need for short-run versions produced at a moment’s notice, the company made a strategic decision to invest heavily in digital print technology.

This decision led to the installation of an HP PageWide T470 six-colour drop-on-demand press, featuring web cleaning, priming, over print varnish, and downstream sheeting.  To fully automate the line, Zumbiel turned to Martin Automatic for unwind and splicing technology capable of managing the large rolls of carton board used in producing various beverage packaging products.

The HP press, which features a maximum web width of 42″ (1066mm), is capable of production speeds up to 600 ft/min (180m/min).  To support this high-speed operation, the Martin Automatic equipment includes the MCBWW unwind butt splicer.  The splicer can handle web widths ranging from 22” to 46” (560 – 1170mm) and can process rolls of 12-24 pt carton board up to 84” (2130mm) in diameter, weighing up to 7,500 lbs (3,400kg), making it a robust solution for digital production.

The system also incorporates a Martin inertia-compensated festoon system, a butt splice unit with two inline cantilevered unwind spindles, and an integral lift system for easy roll loading. The controls for these components are mounted directly on the equipment, enabling seamless automation of roll unwinding, splicing, and tension control.  Bob Hoffman, Sales Manager at Martin Automatic, highlighted some key features that enhance the Zumbiel setup. “The machine features our latest diagnostic system and operator productivity packages that inform the operators proactively if they miss one of the few steps during splice preparation.”

Mick Kennedy, Senior Vice President of Operations at Zumbiel, praised the seamless integration of Martin’s technology. “The system fits perfectly into our digital production line,” he said. “It’s so reliable that I rarely think about it during day-to-day operations.  It’s intuitive to learn and operate, and the support we receive from Martin is outstanding.”  This ongoing and long-term support was echoed by Bob Hoffman, who added: “Our commitment to Zumbiel goes back many decades – they have Martin technology in everyday operation that has been repurposed to more than one press over the years.  It’s a great example of how we anticipate changing needs and deliver machines that are future-proof.”

Typical production orders on the digital line range between 50,000 and 100,000 impressions, with various copies produced.  On a typical eight-hour shift, the HP line requires six to eight roll changes.  Manually changing rolls would take at least five minutes per change, so the Martin Automatic system effectively adds 25 to 30 minutes of productive time per shift, while also improving ergonomics by eliminating the need for operators to manually manipulate the rolls. Ed Zumbiel, CEO of the company, expressed his satisfaction with the new digital production capability and the performance of the Martin Automatic unwind system. “This new HP line boosts our digital capabilities and does so at a price point comparable to sheet-fed litho,” he said. “The Martin Automatic unwind system is a perfect fit for our digital operations. It enhances our production efficiency, reduces downtime, and supports the high standards of quality and service that define Zumbiel.”