Although "Contiweb" primarily reflects the company's focus on continuous web applications, Contiweb also provides advanced auto-splicing solutions tailored to sheetfed printing. With growing demand for higher productivity and lower production costs, HEIDELBERG introduced its first-generation CutStar sheeter at drupa 2000, enabling the use of roll-fed paper cut into sheets just before printing. Initially, the CutStar operated with a single, manual unwinder, but as modern sheetfed offset presses like the HEIDELBERG Speedmaster XL 106 reached speeds of up to 21,000 sheets per hour, the need for automated splicing emerged. Contiweb’s CBN-1100 Auto-Splicer provides an ideal complement to the fourth-generation CutStar.

In this guest blog, Philipp Doley, Product Manager at Heidelberger Druckmaschinen AG (HEIDELBERG), explains the CutStar solution and highlights how integrating Contiweb’s auto-splicer further enhances efficiency and cost-effectiveness for printing companies.

The genesis of the HEIDELBERG CutStar

HEIDELBERG introduced the first CutStar sheeter at drupa 2000. The development of the CutStar was driven by customer demands for a reel-to-sheet solution that would offer cost savings on paper and improve performance when handling thin substrates, such as leaflets and in-mold films. Additionally, the use of reels instead of piles in print shop storages provided operational efficiencies. The CutStar enabled paper to be cut into sheets just before printing, allowing printers to save on paper costs while boosting efficiency.

Initially, the CutStar operated with a single unwinder, requiring operators to stop the press while manually splicing two paper reels together. However, as HEIDELBERG’s printing technology evolved and presses like the Speedmaster XL 106 reached speeds of up to 21,000 sheets per hour, the need for greater automation became clear. This is where Contiweb’s advanced auto-splicing solution came into play, seamlessly connected to the CutStar to further enhance productivity and streamline operations.

A leap forward in productivity

The latest iteration of the CutStar, the Generation 4 model, represents a leap forward in both automation and productivity. Designed with the needs of modern print shops in mind, it offers a host of benefits, including reduced makeready times, high-speed integration, and the ability to handle a wide range of substrates.

One of the standout features of the CutStar Generation 4 is its integration with HEIDELBERG’s Push-to-Stop concept. This concept streamlines operations by allowing presses to operate with minimal human intervention, meaning less downtime and higher output. The CutStar’s integration into this system means operators can achieve faster setup times—up to 50% faster when integrated into the Prinect workflow—thanks to preset values for different substrates that eliminate the need for manual adjustments. The result is a smoother, more efficient workflow that enhances overall productivity.

Notably, the CutStar Generation 4 also improves flexibility in material handling. Printers can process thin substrates, such as label papers, films, and package inserts, with greater ease. The system is capable of processing paper as thin as 30 gsm and films as thin as 40 µm, expanding the range of materials a printer can work with and enhancing versatility. For the pharmaceutical and label printing industries, this level of flexibility is especially valuable, enabling a 30% boost in production speed.

You can learn more about the CutStar Generation 4 by watching this video.

Continuous operation without interruption for reel changing

While the CutStar Generation 4 alone provides a major productivity boost, its capabilities are greatly enhanced when paired with the Contiweb CBN-1100 Auto-Splicer. This system is designed to automate the reel splicing process, allowing printing presses to continue operating without interruption during reel changes. In high-speed production lines such as the HEIDELBERG Speedmaster XL 106 combined with the CutStar, this feature is indispensable.

The CBN-1100 Auto-Splicer seamlessly splices a new paper reel to the running web without interrupting production. During the splice cycle, the system briefly pauses the web and feeds paper from the buffer to the sheeter, enabling the CutStar to continue sheeting. It then splices the new reel to the paper web in the buffer, ensuring uninterrupted printing.

You can watch the splicing process in this video.

The benefits of the CBN-1100 Auto-Splicer are clear. By reducing the downtime required for manual reel changes, printing operations can achieve continuous, high-speed production, increasing overall throughput by as much as 12%. Additionally, the system minimizes paper waste, as there is no need to discard incomplete paper rolls when changing reels. With nearly 100% splice reliability, it prevents web breaks caused by imperfect manual splices and frees up operators to focus on other tasks. This makes the CBN-1100 Auto-Splicer an ideal complement to the CutStar system, further enhancing cost-efficiency for printing companies.

Market developments and customer demands

HEIDELBERG’s development of the CutStar and its integration with Contiweb’s auto-splicing technology were driven by several market trends and customer demands. The growing need for higher production speeds, particularly in label printing and packaging, pushed the industry to adopt technologies that would allow for faster, more efficient printing without compromising quality.

The success of these systems is evident in their widespread adoption. Since its launch, the CutStar Generation 4 has become particularly popular in sectors like commercial printing and label printing. In fact, two-thirds of the systems sold so far have been used for printing labels and package inserts, showing a strong demand for high-speed, cost-effective printing solutions in these industries.

In May 2023, HEIDELBERG sold its 50th CutStar Generation 4 to Seaway Printing Company, a commercial print shop based in Green Bay, Wisconsin USA. Since then, the company has been able to significantly increase its productivity while maintaining its commitment to quality and reliability. Kevin Heslin, President of Seaway Printing, says," Here at Seaway Printing, everything revolves around quality, reliability, and speed. Having understood our requirements perfectly and worked on appropriate automation solutions, HEIDELBERG has become an important partner that helps us fulfill those promises. By utilizing cutting-edge CutStar technology in combination with the high-end configuration of our Speedmaster XL 106-8-P, Seaway Printing has been able to considerably boost productivity."

At the beginning of 2025 HEIDELBERG is expected to deliver its 100th system, marking a significant milestone in the success of the product.