The specialist in personalisation, data processing, mailing and fulfilment has in the last month seen its capacity leap from 80 million to 160 million cards per year.

Managing director Adam Unsworth said: “Most of the investments took place last year, but they have only recently pulled together to double our capacity.

“This increase in capacity is fantastic and is eating into the work rapidly to give us more flexibility for quick-turnaround jobs and large-volume work.”

He added: “We are closing off our end-of year accounts and aim to increase turnover by 6%; and in 12 months time we hope to push it to the £6m mark.”

PCS is a 52-staff business that currently turns over £5.5m and Unsworth said he was looking to recruit more sales and support staff in the coming weeks to handle the growth.

The total investment involved a new HP Indigo, a laminator, collator and hot-foil stamper, as well as 500sqm of extras space next to the Macclesfield base, taking its total floor area up to more than 2,787sqm.

The kit includes a Bürkle Smartlam CHK100/200 laminator, a HP Indigo 5900 seven-colour digital press, a fully automatic Col-Tec sheet collator and a MicroPOISE MK2 hot-foil stamping machine. 

Flexibility on sheet size with the Bürkle laminator means the company can use the kit for both litho and digital work improving on lead times and capacity.

Existing machinery includes a five-colour KBA Genius 52 UV waterless offset press, a Svecia screen press with UV bridge and a range of Oasys finishing kit.

PCS was formed in 1993 and boasts high-profile international clients ranging from major retailers and FTSE 100 companies, to public-sector organisations.

It claims to be one of the first card manufacturers in Europe to use environmentally friendly materials, waterless print processes and innovative camera-match technology to perfect accuracy.

Unsworth stepped from sales director to managing director last October to take over from Rob Nicholls.