J.S. McCarthy Sets New Record in Folding Carton Production

J.S. McCarthy Packaging + Print (JSM) has set a new world record for folding carton production, surpassing its own benchmark established just one year ago. The company produced 569,220 net sellable sheets in a continuous 30-hour, 26-minute run on its Heidelberg Speedmaster XL 106 21K Press.

During the strongest 24-hour period of the run, the team printed 460,149 sheets, exceeding last year’s record of 429,000 sheets and reaching an average production rate of 19,173 sheets per hour.

From left, Randy Robbins, Ian Cowett, Matthew Schencks, Russell Wheeler, Jason Baird, Jake White, Jordan Wooldridge, and Greg Giasson celebrate J.S. McCarthy's milestone. | Credit: J.S. McCarthy

The record was achieved using Heidelberg’s latest press technology along with 18pt SBS PrintKote folding carton board from Smurfit WestRock, with eight makereadies and total spoilage of just 0.5 percent.

“In 2025, we set out to prove what was possible,” said Jon Tardiff, President + CEO of J.S. McCarthy. “This year, we came back with the right job, the right conditions, and a team that was ready to push even further.”

Preparation for the run was no different than any other high-performance job on our floor. Teams across shifts stayed aligned on setup, staging, and material flow to keep the press running consistently at high speeds. From feeder to delivery, every detail had to be right, and the team executed.

“It takes a lot of coordination that people do not always see,” Jason Baird, Press Operator, said. “Everything has to come together perfectly from start to finish.”

Heidelberg played a key role in enabling the performance. The Speedmaster XL 106 allowed the team to run at sustained high speeds while maintaining tight color control and print quality. Integrated inspection systems monitored color in real time, while operators continuously checked sheets to ensure consistency throughout the run.

“Heidelberg has been an excellent partner,” Tardiff said. “Their technology gives our operators the ability to achieve this level of productivity while maintaining the standards our customers expect every day.”

The effort also highlighted the strength of JSM’s workforce. As a 100 percent employee-owned company, every team member has a direct stake in the outcome. Press operators, material handlers, logistics teams, and support staff all contributed to the success of the run.

“Our team is constantly pushing to improve,” Tardiff said. “They are focused on doing things better, faster, and more efficiently, without ever compromising quality.”

The run consumed more than 210,000 pounds of paperboard, equivalent to five trailer truck loads, demonstrating both the scale of the operation and the level of coordination required.

J.S. McCarthy continues to focus on delivering high-performance folding carton packaging for industries such as food, pharmaceutical and cosmetics, where speed, consistency, and reliability are critical. This new world record reflects the company’s ongoing investment in technology, process improvement, and its people.

“We are always looking for the next opportunity to improve,” Tardiff said. “That is what defines our company.”

Source: J.S. McCarthy

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