For over two decades, Doveton Press has built its reputation on a simple philosophy: deliver quality work, meet deadlines and keep customers coming back. Now, with the installation of a new Duplo DBM-700 Booklet System and DC-648 Slitter Cutter Creaser, the family-run commercial printer has taken another significant step forward in its ongoing drive for productivity, flexibility and customer service.
For Doveton Press, the investment is not simply about replacing equipment. It is about removing bottlenecks, increasing capacity and ensuring the business can continue to deliver the fast turnaround times that have helped it grow almost entirely through customer recommendation.
"We give a good service and our customers keep coming back," said Production Director, Mark Savage. "We haven't got people knocking on doors or ringing people up every day. It's all word of mouth, and our Dad drove that into us. Gavin and I have carried that forward by giving people what they want, when they need it and meeting deadlines. It sounds simple, but that's really what it comes down to."
Booklets being produced on Dovetons new DBM-700 Booklet System
Why Was Doveton Press Looking to Increase Finishing Capacity?
As volumes increased across both litho and digital work, Doveton's finishing department became the next area for improvement. The business had already invested in a new B2 press to accelerate production speeds, but greater output on press naturally placed additional pressure on finishing. "We had our Excel 75 installed because it turns work over so quickly," explained Mark. "As volumes built up, the guys in finishing were getting stressed because stitching was a long-winded process."
The solution was a combination of Duplo's latest generation DC-648 Slitter Cutter Creaser and the DBM-700 Booklet System. By introducing automated pre-cutting and high-speed booklet production, Doveton expects to significantly increase throughput while simplifying production processes. "With the two latest investments, they will cut out the folding of sheets for our stitch line," said Mark. "Instead, we just cut everything. It should make us even more streamlined because we pre-cut the work before it goes onto the stitch line." The impact is expected to be substantial. "I would say it will double our productivity in finishing because finishing has always been a bottleneck. Now, with these two systems, we should double it easily. It just makes life easier and more productive for the guys."
Mark Savage - Production Director, Doveton Press
How Will the DBM-700 and DC-648 Improve Productivity?
Like many printers, Doveton faces the challenge of recruiting and retaining experienced finishing operators. For Managing Director Gavin Savage, investments in automation are increasingly driven by the need to make production simpler and more accessible for a wider range of staff.
"Everybody knows it's very difficult now to get new staff members," said Gavin. "With what Duplo offers, it's very easy to get guys who are not familiar with fold and stitch machines to learn it. The machine does the work. There are no massive technical problems or lots of learning. All they really need to understand is the quality coming off the end."
The simplicity of operation has allowed Doveton to build greater flexibility into its workforce, ensuring more people can confidently run multiple finishing systems across the factory. "From a business point of view, having multiple staff able to use multiple machines is a real no-brainer for us," Gavin added. "The skill levels have come down in finishing, but the machines really put in all the work."
The result is a more resilient operation, reduced dependency on specialist operators and greater efficiency throughout production. "The more staff who can use the machines, the fewer staff we need within the production base," said Gavin. "That obviously saves money and helps us stay competitive."
Gavin Savage - Managing Director, Doveton Press
A Relationship Built Over Decades
The latest installation represents another chapter in a long-standing partnership between Doveton Press and Duplo that stretches back more than twenty years.
According to Duplo’s Regional Sales Manager Jason Davies, the relationship actually predates his own 26-year career with the company. "Doveton had a second-hand Duplo system before I first visited them," said Jason. "I originally met Mike Savage, Gavin and Mark's father, and from there the relationship really blossomed." Over the years, Doveton has invested across multiple areas of the Duplo portfolio, including booklet making, binding and multi-finishing technology.
"They've had the whole range of booklet makers throughout the years," Jason explained. "They've got a DPB-500 Hotmelt Binder, they've had several multi-finishers, including the DC-746, and now they've moved to the latest generation DC-648. I'm also proud to say they've now added the latest DBM-700 system while their previous DBM-600 system is still working hard."
For Jason, the latest investment reflects Doveton's continued commitment to delivering exceptional service through automation. "When I talk to other customers, they're talking about getting work from the web or having salespeople out there chasing business. These guys are so focused on service, turnaround and quality that customers simply keep coming back."
Mark and Jason Davies when their DBM-600 was first installed in 2023
Producing Premium Booklets In-House
"The big feature of the DBM-700 is that it allows the production of square spine booklets in-house," said Jason. "We can square spine up to a 200-page brochure and produce more than 3,000 books per hour." Combined with Doveton's existing DBM-600 system, the company now has a formidable booklet production capability. "They've kept the DBM-600, so together they have the power to produce up to 10,000 books per hour, or up to 20,000 two-up, with four stitching heads and five-knife trimming capability."
The flexibility means Doveton can comfortably handle anything from a single digitally printed booklet through to large litho runs of tens of thousands of copies.
Supporting Fast Turnaround Printing
The investment also strengthens Doveton's ability to react quickly to urgent customer demands. "If somebody needs a job urgently, we can react and get it done that day," said Mark. "Especially if it's a digital booklet or something that someone wants out of the door that night. We can print it, stitch it and get it out of the door."
That responsiveness has become increasingly important as customer expectations continue to evolve. "People want something on demand," said Jason. "They want it today, tomorrow or whenever it might be. The automation and simplicity of the Duplo kit allows Doveton to offer that service confidently and consistently."
Reliability and Support That Delivers
Beyond the equipment itself, Doveton points to the ongoing support from Duplo as a major reason for maintaining the partnership. "We've stayed with Duplo because the equipment is good, easy to use and the software isn't complicated," said Mark. "The guys like running it. It makes life easier and because of the speed of it, we can get work through the factory quicker." Support has also played a key role. "We very rarely have a problem," Mark continued. "If there is a breakdown, the guys are here within a day or two and we're up and running again. There was no need to go anywhere else because we know the equipment is good. If it isn't broken, don't fix it."
Gavin agrees. "What we've found with Duplo over the years, especially with Jason, is that what he says happens," he said. "Reliability has been very good and, if there is a problem, you can phone Jason directly and he'll help. It's not just a case of phoning the office."
For Jason, that trust has been earned through years of delivering on promises. "It is a testament to both the kit and the level of service that Duplo offers that they've never really looked anywhere else," he said. "They've simply said, 'We like the way you look after us. We like the kit. We're sticking with you."
Working with the DC-648 Multi finisher
Looking Ahead
For Doveton Press, the latest investment is another step in a continuous programme of improvement designed to support future growth, maintain competitiveness and keep customers satisfied. "When we invest, we make sure we choose the right machines and the right backers," concluded Gavin.
With a faster, more automated finishing department, increased booklet production capacity and the ability to respond even quicker to customer demands, Doveton Press is well positioned to continue delivering the service, quality and turnaround that has defined the business for generations.
