Managing director Giles Sergant said 170 staff at leased sites in Newcastle and Sunderland would move into the 11,000sqm factory (pictured) in the weeks before and after Christmas.

He said that built-in hygiene features at the plant, which will run Heidelberg presses and be CIP4- and JDF-compliant, resembled those more normally found in the computing industry.

"We've designed the facility to operate like a micro-electronic facility from a quality and hygiene standpoint and have integrated clean rooms within our production hall," he said. "I suspect it will be the cleanest plant in the UK."

Reed has installed a new 12-colour Heidelberg SM 102 perfector at the plant and will transfer a five-colour CD 102 that it acquired after the fire in November 2003 but is due to be replaced.

Four press bases have been built that are capable of holding a 12-colour Heidelberg XL 105, but Sergant would not be drawn on what would replace the five-colour, saying only: "We are very pleased with Heidelberg."

Another four-colour SM 102 perfector supplied following the blaze will be sold.

Turnover at DM, packaging and commercial print house Reed is currently around 12m, although Sergant said that the new factory had the potential to expand that figure to around 30m.

Sergant did not reveal a set date to reach that target, but said the "future-proof" building had been designed to allow expansion by a further third.

Heidelberg sales director Jim Todd described the deal with Reed, a former MAN Roland house, as "huge".

Reed's rebirth
- 11/2003 Reed Print & Design in Washington destroyed by fire

- 3/2004 Reed Packaging in Gateshead put up for sale

- 8/2004 Planning permission granted for new plant

- 12/2005 Plant completed, staff from Newcastle and Sunderland plants moved in