Hemlock Printers Doubles Productivity with HEIDELBERG’s Robotic StackStar C Technology
Hemlock Printers, Burnaby, BC, has improved finishing operations with the installation of two new StackStar C robotic arms from HEIDELBERG. The advanced, flexible robots are integrated with the company’s Stahlfolder TH 82 folding systems to support high-volume book signature production. Since installation, the technology has significantly boosted productivity – doubling Hemlock’s finishing output.
“Trailblazing” Robotics
Started in 1968 by Dick Kouwenhoven, Hemlock has been a pioneer in sustainable print practices for twenty years. The family-owned commercial and packaging printer, who specializes in offset and digital printing, has been carbon-neutral since 2007. “Our company has blazed many trails over the last two decades,” said Daren McKewan, Vice President of Manufacturing for Hemlock. “We remain committed to carrying that tradition into the future.”
While continuing to advance its sustainability initiatives, Hemlock is now channeling its “trailblazing” spirit into investments in robotics and AI to improve quoting speed, production throughput, and overall value. The StackStar C units, installed in September, mark the company’s first ever investment in robotic technology. Designed for short and medium runs, the StackStar is a collaborative robotic system that automatically stacks folded product from the folder onto pallets – all without the need for a safety fence.
The StackStar Cs support two of Hemlock’s high-performance Stahlfolder TH 82 systems – a TH 82-P added in 2017 and a second TH 82 in 2019. While the TH 82-P is equipped with an innovative shingled feeder designed to improve folding productivity by 50%, the folders still struggled to match the output of Hemlock’s Speedmaster XL 106-8P – installed in 2019 – that prints at speeds of 18,000 sheets per hour.
“The TH 82-P can go very fast, but it’s difficult for the staff to keep up,” said McKewan. “It puts a lot of strain on the body. We needed a solution that would assist our team in getting materials from the folder to the binder not only quicker but also more ergonomically.”
Looking to maximize its productivity, Hemlock first saw the StackStar C robot at drupa 2024 – becoming the first North American customer to adopt the technology. According to McKewan, “Right away, we knew these units would make sense for our business. I could almost do the ROI in my head at the show, and once we ran the full analysis, it only reinforced the decision.”
Only two months into operation, the StackStar units are already delivering on their ROI. After two folder operators recently left the company, Hemlock was able to easily transition its staff – now running three folders (including a Stahlfolder TH 66) with only two operators per shift. Even with one operator managing both high-speed Stahlfolder TH 82s, the company has still doubled productivity. Quality has also improved as operators now have more time to inspect folds, and the StackStar’s eject-pile feature allows stacks to be checked without interrupting production.
Additionally, the automation has boosted the health and morale of Hemlock’s operators. While they were first hesitant of the new robots, the operators’ jobs are now less physically demanding as the StackStar Cs have reduced upper-body strain and repetitive lifting. Easy to operate, the StackStar C robotic arms were quickly integrated with Hemlock’s existing folders – with operators fully trained and the systems running in just two days.
“I don’t think I’ve ever seen our folder operators smile so much,” said McKewan. “They just love the technology.” Building on the success of the StackStar C, Hemlock is moving ahead with a broader strategy to expand robotics and AI throughout its operations over the next two to five years.
Quality, Trust, and Service
Currently equipped with a second Speedmaster XL 106 and three POLAR cutting systems including a PACE system, with a new Suprasetter 106 scheduled for installation early next year, Hemlock continues to strengthen its partnership with HEIDELBERG that spans nearly fifty years.
“What makes Hemlock different is our customer service and our quality – it’s what we’ve built our foundation on,” said McKewan. “We strive to always produce the best quality prints in the industry, and that’s one of the reasons we’ve invested in HEIDELBERG equipment for decades – whether it’s printing or folding or finishing. We look forward to continuing that relationship built on shared values of quality, trust, and service.”
The preceding press release was provided by a company unaffiliated with Printing Impressions. The views expressed within may not directly reflect the thoughts or opinions of the staff of Printing Impressions.
