The Encore Group invests in Novacut to increase its packaging output capacity

Packaging Solutions

The Encore Group has invested in a third Novacut die cutter from Bobst, responding to a period of sustained growth.

The Encore Group was founded in 1983 and is now on of the UK's largest independently owned envelope and packaging manufacturers. It produces folding cartons and corrugated packaging for a variety of end uses, including food, retail, e-commerce, and medical and healthcare. To maintain this position, the company prides itself on continuously investing to allow it to print and convert products to the highest standard. This includes converting equipment such as an Expertfold 110 A2, a Visionfold 110 A2 and a Handypack GT. A Novacut E and pre-existing Novacut 106 ER provide die cutting capability at the company. Shortly to be installed is a Bobst Novacut 106 ER APT with automatic pallet transfer, which will further the company’s ability to process folding boxboard for food packaging applications.

The Novacut 106 ER is an autoplaten die cutter, engineered to simplify blanking during folding carton manufacture. Able to achieve a production speed of up to 7000 sheets per hour (8000 with speed upgrade), it can handle sheets up to 1060 x 760 mm, with a maximum corrugated board thickness of 4 mm, carton board up to 2000 g/m2 and a paper weight of 80 g/m2. A cutting force of 2.6 MN is applied, with a 23.8 mm cutting rule height. Key features of the machine include a single, full colour HMI; a pull or push sheet registration; high speed, in line stripping; automatic non stop blank pile delivery; automatic quick lock system for the upper tool, integrated into the machine; on-demand motorised cutting force adjustment; and optional non stop feeder to optimise the machine’s net output.

The new machine destined for The Encore Group will provide a substantial boost to the company’s manufacturing, equating to an increase of more than 30% in output capacity.

David Cooper, managing director of The Encore Group, said: ‘It is important we are not standing still but are looking to the future. 

‘We experienced packaging growth of 28% in 2022 and a further 12% in 2023. That means this machine is to be delivered at a pivotal moment for our business, as we focus on further growth. We need to ensure we continually invest in the right equipment to make sure we meet the service and commercial requirements of our customers. This investment ensures our customers benefit from the very best the industry has to offer.’

He added that his company and its customers benefit from a continued partnership with a reliable and reputed supplier that is Bobst.

‘With all the external challenges of recent years, Bobst has still offered the best professional approach to new investment. Communication and continuous innovation have been key to our decision making and this sets Bobst apart from the rest of the competition,’ he emphasised.