Arriving over November and December, the new equipment includes a Muller Ventura MC 200 sewing line, Tecnograf case binder, a new board cutter and Komori H&H miniature folding machine.
The 2019 Ventura, bought secondhand from JW Press, has replaced an older, 15-20 year-old model. The new model has an additional pressing unit, allowing EPF to reduce the bulk of the spine created by sewing up to 20%, giving a flatter, more consistent quality product.
EPF also took delivery of a Tecnograf Tower Plus Case Binding machine in Decemer, this time from Grafitec. It also replaced an older version of the machine. Running alongside the firm’s existing Kolbus casemaker, this has brought the firm up from 1,250 to 2,000 hardbound books a day.
“It gives us that opportunity to take on longer runs for customers, and try and be a little bit more competitive on price as well – that’s the kind of market we’re in now. That said, price may always be key, but quality is usually [the deciding factor],” said David Milson, managing director of EPF.
This ramp-up in production has been backed by a new PBS096 Board Cutter, bought back in October from Perfect Bindery Solutions.
The machine had a long journey to EPF, with plenty of drama along the way.
“That was a nightmare – if you remember the trouble with the Suez Canal, and the boat that got stuck there – it took months and months. Once it arrived, it had to go up North to have guards put on – and then it fell off the back of the lorry, so we had to get another one sent up all the way from South America,” Milson said.
In place over the last six months, however, it has proved a massive help to the business, which had previously been cutting its case boards on a guillotine.
“It used to be really tricky, and quite slow – you’re talking just 5mm of board you’re cutting. If you cut a little bit out of square, it causes so many issues when you’re casemaking,” Milson explained.
“This literally just cuts – feed it, and it will chop, chop, chop – it has increased productivity, saved time, and makes it a better quality job.”
Over the past year, EPF has seen massive growth in demand for its pharmaceutical leaflet folding, with the firm’s two H&H miniature folders running at full capacity to keep up.
“We were finding ourselves forever up against it, working Fridays, Saturdays and Sundays all up until Christmas to do all the pharmaceutical work,” he added.
“We did nearly 25 million leaflets last year.”
The new machine has allowed the team to keep two machines running in set formats, with the third machine taking on all the smaller jobs that had previously forced the team to spend time switching jobs all too frequently.
“We’re much more efficient, and get more leaflets out of the machines in a day, because we’re not having to spend an hour or two in changeovers.”
The machine arrived in November; Milson said he was confident the company has already earned its money back.
While 2025 has presented a calmer start to the year than 2024’s mad rush of 12-hour shifts, seven days a week, Milson was hopeful that business would pick back up.
“April is going to be an interesting time once the National Insurance kicks in along with the extra minimum wage as well,” he said.
“We’re hoping that people are just preparing themselves, and then will realise that it’s not too bad – and then press the button to start printing again.”
EPF employs around 12 staff, turning over £1m.
