SHERIDAN, WYOMING – May 27, 2025 – Seaway Printing has taken a bold step toward fully autonomous production, becoming the first U.S. customer to implement HEIDELBERG’s Plate to Unit system, and integrating the world’s first Inline Splicer with the CutStar generation 4 sheeter. The move is part of a sweeping automation strategy aimed at significantly improving productivity and operational efficiency across Seaway’s expanded Wisconsin facility.
Located in De Pere, Wisconsin, Seaway recently doubled its production capacity to meet surging demand for short-run book and magazine printing. With new HEIDELBERG technology embedded in prepress, press, and postpress operations, the company now operates with fewer manual interventions and has optimized labor usage by allowing each machine to be managed by just one operator.
Breakthrough in Prepress and Plate Logistics
Seaway’s investment in the fully automatic Plate to Unit system on its Speedmaster XL 106-8P press represents a U.S. first. This system streamlines plate changes, reduces the risk of scratches, and cuts paper waste. Supporting this leap in automation are two Suprasetter 106 CtP systems, which feature automatic inline bending and punching capabilities.
“Thanks to the combined efficiency of Prinect and Suprasetter technology, the team at Seaway can carry out plate production fully automatically and even reallocate one person per shift from the plateroom to more value-adding roles in production.”
Enhanced Productivity with Peak Performance Press Technology
At the heart of Seaway’s operation is its Peak Performance Speedmaster XL 106 press, which includes:
- Non-stop pile-changing system for uninterrupted high-speed runs
- Prinect Inpress Control 3 for inline color management
- CutStar generation 4 reel sheeter to improve feeding efficiency
- Integration with Contiweb’s inline splicer to eliminate roll changeover downtime
This configuration has led to a two-and-a-half-fold increase in press availability and helped achieve an Overall Equipment Effectiveness (OEE) of 70 percent—well above the industry average.
“We configured this press so an operator never needs to be in a particular place at a particular time to maintain productivity. The automation creates a buffer, enabling operators to manage the overall production process while the machine handles individual tasks, such as moving the pile at the delivery or changing a reel, without constant operator intervention,” said Seaway President Kevin Heslin.
End-to-End Automation Extends to Postpress
Seaway’s drive for full automation continues beyond printing, into its finishing department. The company operates three Push to Stop Stahlfolder TH-P folding machines, which shift from one folded signature to the next autonomously. These are supported by three StackStar P robotic stacking systems that move completed stacks directly to pallets.
“Installing the StackStar P made us realize how much time operators spend loading materials from the folder onto pallets. It had an even bigger impact on our finishing operations than we anticipated,” explained Ian Heslin from the Manufacturing Support team at Seaway Printing.
With this configuration, Seaway can fold over 100,000 signatures per shift and per machine—with just two operators overseeing all folding and stacking systems.
Sustained Growth through Technological Innovation
Seaway’s continued investments in automation have been a key driver behind its consistent annual growth of 15–20% over the past decade. These technologies have also helped the company counteract labor shortages and appeal to younger, tech-oriented job seekers.
“Ongoing investment in automated technology is essential for staying competitive in the market and achieving our growth and profitability goals. Without it, reaching our productivity targets – particularly for the short-run work that has become our specialty – wouldn’t be possible,” emphasized Kevin Heslin.
“It’s easier to recruit younger staff, because when people come here and see the new equipment, they’d rather work for us than at other production companies in the area,” revealed Ian Heslin.
Looking ahead, Seaway is collaborating with the HEIDELBERG research and development team to explore even greater efficiency enhancements.
“HEIDELBERG machines are unmatched in day-to-day production and the company is always very willing to listen to our recommendations for improvements. It is helping us get the most out of our machines.”
Learn more at www.heidelberg.com