The success of the cooperative venture between Heidelberg and Masterwork Machinery (MK) is beginning to be seen in the marketplace, where converters are using the technology on a daily basis to good commercial effect. One company that has taken the plunge and had the confidence to invest is Zenith Print & Packaging, located near Cardiff in South Wales.

Far from a traditional carton converter, Zenith has forged a global reputation in printed presentation packs for the coin collecting numismatic market and now lists The Royal Mint and banks and mints from other countries amongst its customer base. Managing Director Ken Bell explained: “We are in a fortunate position where the value of the product is essentially the packaging itself – although the coin or bank note included has a negotiable market value, for collecting purposes, it’s the whole package that counts.”

Zenith’s 35 years of experience brings together skills that require a variety of bespoke machines and handwork to suit the innovative and creative projects with which it is involved in sporting merchandise, cosmetics, and high-end food and beverage gifts, including Wales’ own whisky, Penderyn. Brand owners like Sony, Laura Ashley, YSL, Armani, Land Rover, and Next have all come to rely on the company’s unique service and products, and so the choice of new plant is always crucial and made after detailed testing and comparisons for the specialist purposes needed at Zenith.

“Just as the Heidelberg Speedmaster XL 106 revolutionised our print department five years ago, so we are looking to breathe new life into our die cutting with the Promatrix 106 CS,” explained Bell, adding, “and I was impressed with its robust construction when I first saw it at Heidelberg’s Wiesloch-Walldorf facility.” The die cutter, which was installed in August 2015, is the first in the UK, and replaces two older B1 machines. Capable of handling 90 – 2000gsm stock at speeds up to 8,000sph, the Promatrix has worked on runs from 500 to 50,000 sheets since being installed, with a typical average run at Zenith of around 4-5000 sheets.

Looking to raise the productivity bar, Zenith’s die cutter operator Steve James commented: “I’ve worked on all of the big name die cutters and am impressed with the ease of make-ready and speed of job changes on the Promatrix, which are important considerations here.” In particular, the gripper-opening device came in for praise for the way it ensures good sheet travel in the stripping section. Adjustment is easy, without the need for tools, and a Siemens computer controls all systems via an operator interface. “If I had to identify the best points, I’d say the pneumatic locking of the Quick Lock chase and fine adjustment of the stripping frames are key to the quality of our work here,” he added.

With high quality standards to maintain, including FSC Chain of Custody, and SA8000, which acknowledges safety in the workplace, sound management practice, and workers’ rights, Zenith is proud of its many accolades, including The Queen’s Award for Export, and sees its specialist skills as crucial to future growth. “Much of our business is event-orientated, so we endure periods of very high demand, like the 2012 London Olympic Games, but also quieter periods. While these changes are largely predictable, they do make planning workflow tricky, so it’s important that we have technology we can rely on,” said Bell. Full of praise for the way in which Heidelberg’s support has helped to build the Zenith business, he also alluded to the two Speedmaster 106 XL presses that have been installed recently in the Zenith Print Group, and plans for further investment at Zenith Print & Packaging.

Perhaps the last word on Zenith’s Promatrix should go to the operator Steve James: “We have already run plastic, PP, vinyl, and micro-flute corrugated board as well as our standard 350gsm cartonboard on the die cutter. In my view, if the Promatrix can handle our specialised work, it can probably handle anything,” he said.