"There aren't many people [in the Leicester area] that can laminate, spot UV, die-cut, crease, and fold and glue, sending work out as a box that came in as a flat," said factory manager Adam Evans.

The unit has nearly finished installing two Fidia folder-gluers, a Combi Estro for 3-D pocket folders and a 2-D buckle-folding Combi Unica (pictured), both supplied by Fidia International. The two lines will enable it to produce DVD wallets, presentation folders and pocket wallets.

"The first machine has only been in a week, and we've already completed half a dozen jobs. The customers are extremely happy," said Evans.

The site also installed a 100,000 Sanwa TRP 1060 SE cutting, creasing and perforating autoplaten, with full-stripping, over the Christmas holidays. The 7,000sph TRP, supplied by Sanwa UK, can handle sheets of 400x270mm-750x1,060mm.

"We only had die-cutting up to A1, now we can go all the way up to B1," said Evans.

The 30-employee 24/6 operation is reviewing staffing, and may increase levels following the installations. It's also planning to invest further in the near future, possibly in foil blocking.

Meanwhile, Five Star Essex, also part of the Celloglas group, has installed a Steinemann UV roller coat varnisher, which can handle sheets from SRA3 to B1.

"There are three Five Star sites... Benfleet has always been a small site for us, but we felt with the right manager and equipment there would be an opportunity to grow the business," said Celloglas regional director Richard Pinkney.

John Staines joined the Benfleet site in January as factory manager. The firm has since added a SRA1 cylinder die-cutter and Billhofer EK76 combination laminator.