WINTIPAK has selected HEIDELBERG’s Boardmaster inline flexographic press to increase printing capacity and production flexibility at its facility in Halle, Germany. The investment will support the Swiss packaging company’s growth in aseptic materials for liquid food while helping it process more orders with consistent print quality and lower production waste.

The Boardmaster can operate at speeds of up to 600 metres per minute and is designed to handle rapid job changes. According to HEIDELBERG, the platform can reduce start-up waste by as much as 90%, offering potential savings in board, ink, energy and production time.

The press investment combines higher output with lower start-up waste, allowing WINTIPAK to respond more efficiently to changing order volumes and customer requirements.

WINTIPAK supplies aseptic packaging materials used for liquid foods, a market where colour consistency, hygiene, traceability and reliable industrial performance are essential. Its customers require packaging that protects products throughout extended distribution periods while maintaining accurate brand presentation on shelf.

The new press is expected to support several production orders per day without compromising quality standards. Fast job changes will allow the Halle facility to move more efficiently between designs, formats and print specifications, an increasingly important capability as food producers seek shorter runs, greater product variety and more frequent artwork updates.

The investment forms part of a wider expansion programme at the German site. In summer 2025, WINTIPAK held a groundbreaking ceremony for a new production hall in Halle. The additional printing capacity will help the company prepare for higher output and anticipated future demand.

Before choosing the Boardmaster, WINTIPAK reviewed equipment from several technology suppliers. The final configuration includes the Intellimatch scanner system, which supports automated quality control and helps identify print deviations during production. Inline inspection can reduce manual checks, limit defective output and improve consistency across long runs.

Although the Boardmaster was originally developed for folding carton applications, HEIDELBERG is working with system partners to adapt the platform for additional packaging markets. WINTIPAK’s selection demonstrates how high-speed inline flexographic technology can also support specialised paperboard-based structures for aseptic and liquid food packaging.

• High-speed production of up to 600 metres per minute increases available capacity.
• Rapid job changes support multiple orders and shorter production runs.
• Reduced start-up waste lowers material consumption and production costs.
• Inline inspection strengthens quality control and process consistency.
• Operational flexibility helps WINTIPAK respond to future market demand.

Material efficiency is becoming a major consideration for packaging converters. Start-up waste can represent a significant cost, particularly when printing premium substrates or changing frequently between customer jobs. Reducing that waste improves both production economics and environmental performance.

The press also responds to growing demand for paper- and board-based packaging. Brand owners are exploring fibre-based alternatives and recyclable packaging structures, creating new opportunities for printing systems capable of delivering high output, precise registration and stable colour at industrial scale.

HEIDELBERG said international demand for the Boardmaster reflects continued investment in more sustainable packaging formats. The company is positioning the platform as a way for converters to reduce production costs while maintaining the quality required by consumer brands.

For WINTIPAK, the investment is intended to provide the printing capacity needed for its next stage of growth. Combining high-speed output, automated inspection and lower start-up waste should allow the Halle operation to improve productivity while maintaining the demanding standards associated with aseptic food packaging.

The project also illustrates how printing technology is evolving from a standalone production step into a broader efficiency platform. Faster changeovers, connected controls and real-time quality monitoring can help packaging manufacturers reduce waste, improve uptime and serve increasingly complex customer portfolios.

Image suggestion: a high-speed inline flexographic press printing paperboard for aseptic liquid food packaging inside WINTIPAK’s modern Halle production facility, with operators monitoring automated quality controls.