Colorman Ireland and BOBST: Advancing smart, connected packaging production together

Established in 1959, Colorman Ireland has grown into one of the country's leading print operations, serving healthcare, pharmaceutical, IT and government sectors with folding cartons, leaflets, IFUs and booklets. Quality and reliability are not aspirations at Colorman, but the foundation on which the business is built.

That foundation is what drew the company to BOBST nine years ago. John Keating, Operations Director at Colorman Ireland, explains it simply: "We wouldn't consider BOBST a supplier, but rather a key strategic partner. We made the choice to partner with them in kitting out our folding carton division, which is an integral part of the Colorman Ireland business."

For Colorman, that partnership is about far more than hardware. Over nine years, the relationship has evolved into something genuinely collaborative. This creates a relationship where platform improvements are made based on real shop floor experience, and where the shared goal of zero-fault packaging gives both businesses a common language. The end resultis a production floor that is more connected, more automated, and more capable than any single machine could make it.

A facility built for zero-fault production

Over the course of the partnership, Colorman has built a comprehensive BOBST ecosystem on its production floor, anchored by the EXPERTFOLD 110 folder-gluer. The machine's performance gave the team the confidence to take the next step: a fully automated EXPERTFOLD 80 line, the first configuration of its kind in Europe, equipped with EASYFEEDER, ACCUCHECK, ACCUJECT and CARTONPACK 4.

The EXPERTFOLD 80 line represents a significant step forward in automation for Colorman's folding carton operation. The EASYFEEDER handles sheet feeding with minimal operator intervention, while ACCUCHECK monitors quality inline throughout the run. ACCUJECT automatically removes any non-conforming cartons, and CARTONPACK 4 automates counting and stacking at the end of the line, reducing manual handling and delivering consistent, reliable output at pace. These features combine to create a complete, end-to-end automated production line that reduces operator workload, minimizes the risk of human error, and keeps quality tightly controlled from the first sheet to the last.

Liam Myers, Carton Manager at Colorman Ireland, explains the thinking behind the investment: "When we bought the EXPERTFOLD 110, we knew we had a good machine, and we wanted to continue the success we'd had with it. Having ACCUCHECK has made all the difference."

ACCUCHECK and the full quality picture

ACCUCHECK inline quality assurance, controls print, registration, blank integrity and finishes – such as foil, embossing and varnish and detects even minor imperfections. ACCUCHECK monitors every single blank and working in tandem with ACCUJECT, non-conforming cartons are automatically ejected. "When we go into a job, we can go in with confidence. We can produce reports, and our customers feel more reassured knowing everything is monitored and recorded," says Liam. "ACCUCHECK has enhanced our whole quality assurance on the machine. With it, we're genuinely striving for zero-fault packaging."

The hot stamping transfer press has since proved its worth in production. Speeds increased significantly, quality improved through the ACCUREGISTER system, and the ergonomics,with multiple HMI screens allowing operators to control the machine from any point, have made daily operation considerably easier.

Working in partnership with the NOVAFOIL, the DMT reduces setup times, enabling operators to prepare the next job while the current one is still running. This increases uptimeand keeps production flowing. On technically demanding work, the ability to verify the correct die positioning visually before the job starts is both critical and fast.

The Digital Inspection Table: confidence at every stage

Colorman's visit to BOBST's Packaging Centre in Lausanne was originally focused on the NOVAFOIL, but it was there that the team first saw the Digital Inspection Table in action and recognized immediately that it would transform their quality assurance workflow.

For Colorman, the BOBST Digital Inspection Table (DIT) has become indispensable, used across printing, die-cutting, hot foil stamping, Braille embossing and more. It functions as a validation layer between production stages, ensuring every job is thoroughly checked before it moves forward.

The DIT projects a digital file directly onto a physical sheet, giving operators an immediate visual comparison against the approved proof. Print registration, cut-to-print, creasing, foil position and embossing as well as Braille correctness are all verified quickly and accurately, without physical overlays or print minis.

"The Digital Inspection Table is a validation piece that ensures every job we've printed and manufactured is double-checked before it goes through the next process," Liam explains. "For die-cutting, operators use it to confirm correct registration before a job runs. For foiling, it checks that the correct dies are being used, and that positioning is right. The operators genuinely enjoy using it, and it enhances their overall quality assurance across everything they do."

Data, support and a shared ambition

Various functions are linked through BOBST Connect, including reports from the DIT and the ability to monitor benchmarking which gives Colorman real-time machine performance data on and off site, feeding directly into the continuous improvement programs the team runs on the floor.

Feedback from Colorman on the platform has been acted on quickly by BOBST's technical team, a detail John highlights as emblematic of the relationship. “We build our business on service and quality. We haven't got the facility to let people down; we just don't do it. It's key that we get support as soon as we flag an issue and, generally, we get great feedback straight away. The BOBST ethos of zero-fault packaging aligns with Colorman's own ethos of perfection and dedication. That's why this partnership works, and why we'll continue to invest together.”

Stuart Alvey-Taylor, Sales Manager at BOBST, added: “Colorman Ireland is exactly the kind of partner that brings out the best in what we do. Over nine years, their team has pushed us with sharp feedback on BOBST Connect, with demanding applications for the Digital Inspection Table, and with a production environment where zero-fault isn't a marketing phrase but a daily expectation. Seeing how they've built their folding carton division, layer by layer, with each investment reinforcing the last, is a genuine source of pride for us. This is what a long-term technology partnership should look like, and we're committed to being part of whatever comes next for Colorman Ireland."

To learn more about BOBST and its activities, please visit: Folding Carton