Direct Ed has installed the UK’s first Duplo iSaddle Senshi saddle stitcher, in an automation boosting investment.
As a supplier to the education sector, the machine will be used to upgrade the company’s booklet production after the older systems struggled to keep up with growing demand.
Installed at the end of May, the new machine will replace one of two Muller saddle stitchers, a sheetfed Horizon booklet system and an older DBM-5000 booklet system, marking a shift to more automation on the factory floor.
Shortages in skilled labour and a desire to boost market resilience played an important role in influencing Direct Ed’s circa £200,000 investment.
Direct Ed managing director Mark Mugan said: “You used to need years of experience to run finishing kit like the Mullers. Those people just aren’t around anymore.
“We even have our own machine shop onsite because most of the time, we have to look after this kit ourselves. With the Senshi, it’s different. It’s automated, it’s accurate, and it gives our team confidence.”
Training on the Senshi took two weeks and Direct Ed director, Vickie Mugan, said the new kit represented an investment in the future of the Lancashire, Accrington-based business and its 12 employees.
“It shows we understand the work is hard, automating processes makes it easier. It makes this a better place to work. We might be here until midnight some days, but we get the jobs out. That’s just who we are,” she said.
Mark Mugan added: “With the Senshi, we can produce more with less. That is the way of our business – to be more efficient. But you still need good people, and this investment shows ours that we value them and our future.”
Faster job turnaround times will also allow the business to better support schools with tighter deadlines, as well as helping Direct Ed keep prices steady as school budgets are tightening.
“We needed more choice at a faster pace for our customers,” explained Mark Mugan. “The Senshi gives us that. We had a look at a number of manufacturers, but the Senshi was the clear winner because we needed the throughput. And with budgets being squeezed in schools, we had to find ways to do more with less.”
No extra space or power was required to accommodate the kit in Direct Ed’s 790sqm premises and the old machines were traded in.
Mark Mugan added the company’s positive relationship with Duplo – which it has worked with for over 20 years – had an influence on the final choice and gave them confidence it was the right one.
“If we hadn’t seen the Senshi, we would have gone for the DBM-700. But the Senshi ticked more boxes for us,” he said.
“It’s not cheap kit, but the relationship matters. When we have a problem, we know we’ll sort it together. That’s how we treat our own customers, and it’s how we are treated by Duplo.”
When looking for a machine to help with bookletmaking and leaflets, the Senshi stood out as it can produce up to 5,050 A5 booklets per hour and up to 10,100 booklets per hour in 2-up mode. It can handle thick books up to 120 pages, supports A4 landscape, and can run multiple job types with minimal setup.
Duplo said the Senshi integrates its latest saddle stitching technology with high-capacity collating towers, barcode recognition and a modular design.
Commenting on the impact the machine is having, Mark Mugan said: “Right now, the Senshi is good – everyday we’re figuring out (like all new kit) how it behaves – but we will and are getting better. We’re getting more confident and soon, we’re going to get it to sing!”
Direct Ed specialises in producing high-volume school exercise books and educational print materials, with an annual output reaching two million books and a turnover of approximately £1.5m.