From Platen to Profit: How Flexpress is Redefining Die-Cutting with Duplo Automation
For Leicester-based trade printer Flexpress Ltd, growth has never been about standing still. Under the leadership of Managing Director Steve Wenlock, the business has built its reputation on quality, speed, and a willingness to challenge traditional production thinking. That approach is clearly demonstrated in its recent decision to replace a traditional platen and cylinder machine with the Duplo DSM-1000 B2 die-cutter, marking a significant shift in both capability and mindset. Combined with continued investment across digital and litho platforms, Flexpress is now entering its next phase of growth.
At the centre of this transformation was a key decision: moving away from legacy die-cutting. “You can pick up a refurbished cylinder or platen machine for £20,000–£25,000. Then you look at something like the DSM-1000 and think, that’s a big jump,” explains Steve. “But the benefit is not the machine itself. It is what it allows you to do in the same time.” For Flexpress, the shift was not just technical, it was a change in mindset. “If I can reduce the staff time on the old cylinder by 50%, I can redeploy that time elsewhere. That is how you justify it. Once you stop looking at the price in isolation and start thinking about output, efficiency and opportunity, everything changes.”
Replacing the old machines was not simply about speed. It was about removing a long-standing constraint on the business. “Die-cutting was always a bottleneck. It dictated what we could and could not take on,” says Steve. “Now, once a job is set, especially repeat work like presentation folders, we are changing over in minutes. Instead of spending time on makeready, we are running jobs. That is the real difference.” That shift has fundamentally changed how Flexpress approaches production. “Before, we would think twice about taking more jobs on because of the setup time. Now, we are actively pushing for the work.”
With faster changeovers and more consistent output, Flexpress has not just improved efficiency, it has expanded its offering. “It changes your mindset. You stop avoiding work and start asking what else you can produce,” Steve continues. “We are now looking at things like bottle boxes, ticket wallets, key card holders. Products we would not have prioritised before. Because we can produce them efficiently, they become commercially viable. Plus, existing products, like cut-to-shape fliers have become much cheaper for our customers.” This shift is already opening new opportunities. “If we can bring the price down and improve the product, suddenly it becomes much more attractive. That is when demand follows.”
Steve Wenlock overlooks operations on his DSM-1000 B2 die cutter, DDC-8000 B2 DuSense, DC-20K B2 Finishing System and his DBM-700 Automatic Booklet System
A key part of that value creation comes from Flexpress’s investment in digital embellishment. With the installation of the Duplo DuSense DDC-8000, the business has been able to elevate standard print into premium, tactile products that command greater attention and margin. “We are always looking at how we can make print more effective for our clients,” says Steve. “Adding spot UV and foil allows us to take something ordinary and turn it into something that really connects with the end user.” The ability to apply raised spot UV and foil inline, with minimal setup time, has made embellishment far more accessible across a wider range of jobs. “It gives us the flexibility to add value without slowing production down. That is a big deal.” By combining texture, gloss and visual contrast, Flexpress is able to produce work that not only looks different but feels different, helping customers create more engaging and memorable print.
Rather than reducing skill, Flexpress sees automation as a way to make production more consistent and accessible across the team. “It is not about replacing people. It is about making better use of the people we have,” says Steve. “You still need knowledge. You still need judgement. But you are removing the repetitive, time-consuming elements. It means more of the team can produce high-quality work, consistently.” In an industry facing ongoing workforce challenges, that shift is critical. “You cannot rely on one or two people knowing how to set everything up. You need systems that support the whole team.”
Flexpress’s investment in finishing is just one part of a wider strategy to increase both capacity and capability. Alongside its finishing upgrades, the company continues to strengthen its print platforms, with investment in HP Indigo digital technology to support short-run, high-quality work, as well as a new RMGT 970PF-8 long perfector press to drive efficiency in longer runs and reduce turnaround times. This dual approach allows Flexpress to cover a broader range of work while maintaining control over quality and delivery.
“You have got to focus on moving forward. Standing still is not an option,” Steve explains. “We are building the business around where we want to go, not where we have been.”
That same thinking applies to booklet production, where Flexpress has installed what is believed to be one of the largest configurations of Duplo’s DBM-700 booklet system globally. “It is not about having the biggest system. It is about having the right system for the work,” says Steve. “We produce a huge volume of booklets, and we need to do that efficiently, consistently, and without complexity.”
For Martyn Train, Managing Director of Duplo UK, our relationship with Flexpress reflects a shared understanding of how print businesses must evolve and continually innovate. “Flexpress is a great example of a company that understands how to move forward, and decisively” he says. “This is not about replacing traditional processes for the sake of it. It is about creating a production environment that is more resilient, more scalable, more automated and better equipped to handle the ever increasing demands of print buyers and consumers. Steve and the team are constantly looking at how they can improve, whether that is through finishing, print, or workflow, and that mindset is a major factor in their continued success.”
With ongoing investment in equipment, workflow, and infrastructure, Flexpress is positioning itself for sustained growth in an increasingly demanding market. As Steve concludes, “Yes, there is disruption. Yes, there is investment. But you either move forward and adapt, or you get left behind.”
What did Flexpress replace with the Duplo DSM-1000?
Flexpress replaced a traditional platen die-cutting system with the Duplo DSM-1000 B2 die-cutter to improve makeready times, production efficiency, and application flexibility.
Why did Flexpress invest in the DSM-1000?
The company wanted to remove bottlenecks caused by traditional die-cutting processes while enabling faster changeovers and opening new revenue opportunities.
What applications does Flexpress produce on the DSM-1000?
Flexpress produces presentation folders, bottle boxes, ticket wallets, key card holders, and other shaped or creased print applications.
How does the DuSense DDC-8000 support Flexpress?
The DuSense DDC-8000 allows Flexpress to add raised spot UV and foil embellishment, helping create premium print products with greater end-user appeal and higher perceived value.
Why is automation important to Flexpress?
Automation helps Flexpress improve consistency, reduce repetitive manual processes, and support a more flexible production workflow without compromising quality.
What other investments has Flexpress made?
Alongside Duplo finishing systems, Flexpress has invested in HP Indigo digital print technology and an RMGT 970PF-8 long perfector press to increase production capability and efficiency.
