As leading suppliers to the education sector, Direct-Ed have built their reputation on reliability, flexibility, and the ability to handle millions of school books every year. When it came to upgrading their booklet production, Managing Director Mark Mugan and Director Vickie Mugan made the strategic decision to invest in the UK’s first Duplo iSaddle SENSHI – replacing one of their two aging Muller saddle stitchers, a sheet fed Horizon booklet system and an older DBM-5000 booklet system from Duplo. This signalled a major step forward in automation, resilience, and throughput for the company.
“With the SENSHI, we can produce more with less. That is the way of our business – to be more efficient. But you still need good people, and this investment shows ours that we value them and our future,” says Mark.
Key Benefits at a Glance
- Barcode-driven automation and touchscreen controls reduce reliance on skilled operators and simplify training.
- Faster job turnaround times allow Direct-Ed to better support schools with tighter deadlines.
- Investment in automation boosts morale and supports staff, creating a more resilient and future-ready business.
Founded in 1995 and based in Accrington, Direct-Ed specialises in producing high-volume, personalised school exercise books and educational print materials. Their annual output reaches up to 2 million books, supplied both directly to schools and through trade channels. As demand grew and older Muller systems began showing their age, the pressure mounted.
“The Mullers needed two or three highly experienced people to run them. They were hard to change over and you really had to know what you were doing. With the SENSHI, our operators picked it up quickly. It’s easy to use, it’s precise, and it’s already running well,” says Vickie.
Resilience Through Automation
At a time when skilled operators are becoming increasingly difficult to find, the SENSHI provides intelligent automation that takes much of the manual skill out of finishing. From barcode-driven job changes to intuitive touchscreen controls, the system streamlines operations and cuts waste. This shift is not only essential for modern production; it's also vital for resilience in an industry battling labour shortages and a diminishing pool of finishing expertise.
“You used to need years of experience to run finishing kit like the Mullers. Those people just aren’t around anymore. We even have our own machine shop onsite because most of the time, we have to look after this kit ourselves. With the SENSHI, it’s different. It’s automated, it’s accurate, and it gives our team confidence,” says Mark.
School budgets have been tightening, in turn Direct-Ed has worked hard to hold its prices steady. The SENSHI plays a central role in protecting those margins by reducing turnaround time and minimising manual intervention.
“We needed more choice at a faster pace for our customers,” says Mark. “The SENSHI gives us that. We had a look at a number of manufacturers, but the SENSHI was the clear winner because we needed the throughput. And with budgets being squeezed in schools, we had to find ways to do more with less.”
Designed for Production, Built for Growth
The iSaddle SENSHI integrates Duplo’s latest saddle stitching technology with high-capacity collating towers, barcode recognition, and a modular design. It’s capable of producing up to 5,050 A5 booklets per hour and up to 10,100 booklets per hour in 2-up mode – making it ideal for fast-paced educational print environments. It can handle thick books up to 120 pages, supports A4 landscape, and provides the flexibility to run multiple job types with minimal setup.
Despite its impressive capabilities, the SENSHI is engineered for ease of use. Job changes are automated, and operators are guided by a PC-based graphical interface. This reduces errors and shortens learning curves.
“We counted them – 17 plugs,” laughs Mark, “but the power draw is actually lower than the older kit. The girls on the SENSHI have taken to it quickly. They’re improving every day, and when there’s an issue, Richard, Duplo’s Field Service Engineer is here. We know it’ll get sorted. Right now, the SENSHI is good – everyday we’re figuring out (like all new kit) how it behaves – but we will and are getting better. We’re getting more confident and soon, we’re going to get it to sing!
Investing in People, Not Just Equipment
At the heart of Direct-Ed’s success is a loyal and tight-knit team. Many employees have been with the company for years, and there are even family connections across the shop floor. For Mark and Vickie, the SENSHI is as much a message of trust and commitment to their team as it is a production upgrade.
“The investment gives the guys out there – our operators – the indication that we value the business and we value them,” says Vickie. “It shows we understand the work is hard, automating processes makes it easier. It makes this a better place to work. We might be here until midnight some days, but we get the jobs out. That’s just who we are,” she adds.
“You can’t do the job without good people. But when you can’t find more good people, the SENSHI makes up for it. That’s why we bought it,” says Mark.
A Strategic Investment, Not Just a Machine
With 12 employees, Direct-Ed runs a tight operation, and equipment decisions are made carefully. The decision to go with Duplo wasn’t taken lightly – but after visiting the showroom and seeing the SENSHI in action, it became clear it was the right move.
“If we hadn’t seen the SENSHI, we would have gone for the DBM-700. But the SENSHI ticked more boxes for us,” says Mark. “This is a big investment, but we’re confident it’s a good one.”
Financed through Compass Business Finance, the SENSHI was chosen not just for its performance, but for the trusted partnership between Duplo and Direct-Ed.
“It’s not cheap kit, but the relationship matters. When we have a problem, we know we’ll sort it together. That’s how we treat our own customers, and it’s how we are treated by Duplo,” says Mark.
Built on Experience, Backed by Support
Direct-Ed’s relationship with Duplo has grown into more than just a supplier-customer dynamic – it's a collaboration based on mutual trust, responsiveness, and shared values. For Mark and Vickie, it’s this level of personal service and ongoing support that makes working with Duplo a pleasure.
“We genuinely enjoy working with Duplo. They listen, they care, and they get things done,” says Mark. “It’s never just about shifting a box – it’s about making sure the machine works for us, and that we’re getting what we need from it. That’s a rare thing.”
From the very beginning, the relationship between Direct-Ed and Duplo was guided by Regional Sales Manager Wendy Hogg. From responding to the initial online enquiry to personally managing the project from start to finish, Wendy made it her mission to ensure the transition to the SENSHI was smooth, informed, and supported at every step.
"When Direct-Ed reached out about the SENSHI, I knew straight away they were serious about improving their production. From sending test booklets and samples, demonstrations and overseeing the install, I was with them every step of the way," says Wendy. "I still visit regularly – not because I have to, but because I want to make sure everything is running exactly as it should be. It’s been a true partnership."
From installation to aftercare, the Duplo team has been on hand. Since Direct-Ed have a history with Duplo towers from their old DBM-5000 system, the familiarity made training faster and adoption easier.
“We’ve always liked the Duplo towers. If you know them, the SENSHI is an easy next step,” says Mark.
With aspirations to expand into the neighbouring unit and grow 20% year-on-year, the SENSHI isn’t just a productivity tool – it’s a signal of intent.
“We enjoy the business, we enjoy growing the business. The SENSHI helps us do both,” says Mark.
In an industry defined by tight deadlines, vanishing skills, and ever-tighter margins, Direct-Ed has chosen to lead rather than follow. The Duplo iSaddle SENSHI isn’t just helping them hit production targets – it’s strengthening their team, their offering, and their commitment to the future.
"We won’t promise what we can’t deliver. The SENSHI helps us make sure we always do what we say we will. That’s how we keep our customers," says Vickie.
With automation, support, and smart investment, Direct-Ed is proving that even in a challenging print landscape, growth and peace of mind can go hand in hand.
“Direct-Ed are a brilliant example of a forward-thinking print business. It’s been a real pleasure supporting them through this journey – and I’m excited to see what they do next,” says Wendy.
