"The Tsukuba plant will be a 21st-century manufacturing base without parallel," said president and chief executive Yoshiharu Komori.

"The factory allows us to exploit the modular design of the 40in presses, and could well lead to ever more innovative configurations," added Komori UK head of marketing Philip Dunn.

The 38,500sqm plant, which began press production on 5 December 2005, is dedicated to the manufacture of the firm's 40in and 44in models. It produces 12 press units per single day shift, equating to one unit every 45 minutes, although this number could potentially be increased.

The 185,000sqm site that houses the factory has the provision for expansion, and the main building is designed with this in mind.
The 520-staff plant boasts a research and development facility with the latest CAD systems, a demonstration centre large enough for three long presses, technical training rooms, and testing areas.

It uses "just in time" parts delivery to feed two 80m-long assembly lines and an "advanced information network" with its suppliers, which it claims reduces bespoke press delivery lead times.

Thermostatically and humidity-controlled cylinder milling ensures micron-precise one-piece solid cylinder manufacturing, which, Mr Komori said, emphasised "quality and reliability the original starting point for manufacturing".

Environmental issues were high on the firm's agenda, and Tsukuba uses solar and wind energy to power office and external lighting, and gas-powered air-conditioning. It also houses its own waste handling centre to pre-sort recyclable waste.

Tsukuba, which is 60km outside Tokyo, replaces the firm's Toride factory, which was built in 1967.

Komori Factfile
- Investment: 39m

- Floorspace: 38,500sqm

- Land: 185,000sqm

- Staff: 520

- Productivity: one press unit every 45 minutes