Zumbiel, an independent carton converter based in the US, has chosen Martin Automatic’s unwind and splice technology for its new HP digital production line.

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 square-foot facility in Hebron, KY, USA. The company employs 380 staff members, and the facility has become a hub of excellence with its digital production line nearing the goal of achieving an 85% OEE target.

Traditionally, Zumbiel’s carton production relied on sheet-fed offset and wide-web flexo presses. However, in response to changing market demand, 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-color drop-on-demand press. The equipment features 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″, is capable of production speeds up to 600 fpm. 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” and can process rolls of 12-24 pt carton board up to 84” in diameter. The equipment weighs up to 7,500 lbs, making it a robust solution for digital production.

The partnership

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. This enables seamless automation of roll unwinding, splicing, and tension control.  Bob Hoffman, sales manager at Martin Automatic, says, “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, adds, “The system fits perfectly into our digital production line. 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. He says, “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.”