We have a wide range of print and fulfilment machinery, from high tech colour digital printing presses and intelligent envelope inserting machines, to polywrapping lines and traditional finishing equipment.
We produce about 5 million peices per month. This can be anything from printing 100 business cards to polywrapping 2 million catalogues, and from complex variable data printing and intelligent inserting jobs to simple direct mail fulfilment. Our mailing house is ISO9001:2008 quality accredited and we welcome the chance to show clients around our facility so you can see the machinery in action for yourself.
Photos of our plant>>
Polywrapping Machines
5 x Sitma polywrapping lines
Maximum of 10 insert feeders, plus main item (i.e catalogue/magazine/book).
One equipped with covermounter/tip-on/gimmick feeder (with or without glue) and a penfeeder.
Selective inserting stations installed on 3 of the Sitmas.
All equipped with Domino Bitjet 212 Inkjet addressing heads (see below).
Envelope Enclosing/Inserting Lines
Pitney Bowes Mailstream Evolution™ envelope inserting system
Processes DL up to C4 envelopes at speeds up to 12K per hour
Camera and barcode/datamatrix reader to ensure 100% integrity
6 friction feeders as well as a 36k letter feeder and envelope feeder
The 36k letter feeder can feed multiple letters if printed with a 2d barcode (2d barcode reader on the first insert station for matching of items)
Selectively feeds up to 6 inserts
Buhrs BB300 envelope inserter
The BB300 is capable of inserting C6/DL to B4 formats, and every size in between, at a maximum speed of 8,000 items per hour, with up to 6 inserts.
Product thickness
- max. 3 mm per rotary feeder
- max. height 10 mm,
Product size:
- max. 310 x 220 mm (w x l),
- min. 100 x 80 mm (w x l)
CMC 250 twin channel envelope inserter
2 channel feeding system
Cut-sheet and continuous fanfold feeder A4 only on fanfold
Merger for "2up" (A4 only)
Sheetfeeder incl BCR reading (only A4 at the moment)
6 vacuum based feeders DL, C5, C4 etc
CMC 250 envelope feeder unit
2 rejection units
1 vacuumtable, prepared for Ink-jet
PC-add operation system
Pitney Bowes DI4500 inserting machine
The DI 4500 is the first multi format production inserter in the world. Two insert tables allow letter format envelopes and C4 pocket envelopes to be processed at the same time with the documents being directed to the most appropriate envelope automatically.
The truly versatile DI 4500 has three insertion modes: Letter format, C4 pocket format or mixed The mixed format mode avoids the need to manually pre-sort documents or manipulate the print run to reflect the envelope size. The DI 4500 simply directs the accumulated set to the appropriate inserting area. Only one print run is required with considerable benefi ts in productivity In markets where postage charges are size based, the DI 4500 ensures the smallest format envelope is used, minimising the cost.
Priciple advantages are:
- Format Choice of formats from Letter to C4 pocket envelope
- Speed Up to 10,000 envelopes per hour
- Max thickness Up to 8mm pack thickness (C4)
- Insert stations 1 to 7
- Reading All types - OMR, BCR, OCR, Data
- Computer 2 17” Touch Screens
- Control Latest generation electronics
- Job memory Unlimited
- Franking Integrated control of two franking
- Output Conveyor or stacker options machines - one for each insert table Matrix
Automated Tabber and Label Applicator
Three way tabbing machine for high speed tabbing of self-mailers (one piece mailers) and leaflets etc. We stock clear horizontal and verticle perf tabs.
The Kirk Rudy tabber can also automate the application of Recorded Delivery and Special Delivery labels and incorporates a scanner.
Colour Digital Printing
Hewlett Packard (HP) indigo 7500 colour digital press
The HP Indigo 7500 is arguable the best quality colour digital printer available.
This provides an excellent solution for variable data print, print on demand, and also makes low run print work affordable
Full details about our HP Indigo 7500 are available here: http://www.btbmf.co.uk/services/digital-printing-hp-indigo-7500.html
We also have a Morgana Documaster that will crease and/or perforate, it will also crease fold and saddle stitch, so we can produce full colour booklets (maximum 20 physical page booklets at 80 gsm).
Our Card Xtra machine enables us to produce full colour postcards and business cards from SRA3+ stock.
2 x Xerox 700 colour digital printers
Image quality: 2400 x 2400 dpi resolution
Up to A3 size documents
CYMK toner based
High Volume Mono Laser Printing
Océ Pagestream 440 Fanfold/Continuous Reel Laser printer
Printing speed: 440 pages per minute in A4 portrait two up 308 pages per minute in A4 landscape
Paper input: single-layer continuous forms with or without perforation, coloured or preprinted
Paper forms length: 3” to 16” in increments of 1/16”
Paper forms width: 6.5” to 18”, fully variable.
Also includes Hunkeler QSM slitting and sheeting unit, counter, delivery conveyor.
Xerox Nuvera™ 144 Digital Production Systems x 2
Modular, scalable printing solution maximizes productivity in both publishing and transactional print environments.
Configurable scanning to optimize workflow -- Integrated, Distributed, Both, or None.
Handles a wide range of data streams -- simplifies and streamlines jobs by eliminating extraneous hardware, intermediate software, and the chance for data conversion errors.
Built-in reliability -- engineered to ensure all parts last longer and service is less frequent.
Market-proven DocuSP software delivers comprehensive job programming and administration features with minimal training.
Works in conjunction with the Xerox FreeFlow™ Digital Workflow collection of solutions to fit easily into your workflow.
Handles a wide range of paper stocks and sizes, with total feeding capacity of over 17,000 sheets.
Provides consistently accurate images and precise registration -- +/- .65 mm image-to-sheet and front-to-back registration with 8.5x11 paper.
Load While Run feature allows for non-stop operation while paper tray is refilled.
Can be configured with up to two finishing modules for stacking, and supports DFA-compliant finishing devices.
Inkjet Personalisation
Connected to Sitma polywrapping lines
Domino Amjet Bitjet 212 Inkjet Printing Systems
High definition quality up to 54mm (2.3”) print band height at 120dpi, 256 points addressable.
Up to 256dpi horizontal resolution.
Linear Speed – 4m/s (800fpm) @ 100dpi, 3.2m/s (625fpm) @ 128dpi, 1.6m/s (312.5fpm) @ 256dpi
Fonts - All common font formats provided by Windows NT available.
Barcodes – Support of the following barcodes: code 39, extended code 39, code 128, Interleaved 2 of 5, Normal 2 of 5 Codabar, POSTNET, OCR, PLANET, 4-State and UPC/EAN.
Graphics – Postal indicia, logos, and more.
Offline Inkjet Line
Same inkjet system as above but attached to a Cheshire mailing table with envelope/postcard feeder and delivery conveyor.
Colour Inkjet Envelope Printer
Riso Inkjet Com Color 7050
- Toner based CMYK
- 300 DPI
- DL to C4 envelopes
Print Finishing
High speed folders
MBO530 – Continuous feeder @ 30.000 per hr with 6 fold plates and 4 plate cross fold unit.
MBO Z2 Knife Fold
Buhrs Quarter Folder
Muller Newspaper Folder
Hunkler QSM High Speed Sheeter
Schneider Senator E-line 78 power Guillotine
Tecnau Multi cut sheeter
16 variable cuts in 1 application, webb sizes 508 width
Fan fold continuous paper only
Split/Merge/Fold In-line
Morgana Documaster and Card xtra
• Documaster will crease and/or perforate, it will also crease fold and saddle stitch
• Maximum 22 page booklets at 80 gsm
• Card machine cuts postcards and business cards from A3+ stock
3 X Pakseal Series 2000 Automatic Strapping Machines
6 x Strapex SMU 359 Automatic Strapping Machines
2 x Akebond MS510 Automatic Strapping Machines
Morgana Documaster
Will crease, perforate, fold and saddle stitch
SRA3+ sheets
Max 20 physical page booklet on 80gsm stock e.g. A4 booklet x 80 printed pages.
Morgana Card Xtra
Cuts postcards and business cards from SRA3+ sheets
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Mailing Fulfilment
The mailings we fulfil vary significantly from simple mass mailings to complex database driven campaigns, for our largest client we mail over 20 million mail pieces per year, whereas other clients send just a few hundred mail pieces per month.
