In a UK first, education stationary supplier Direct-Ed has invested in Duplo iSaddle Senshi, replacing one of its two aging saddle stitchers, a sheet fed booklet system, and an older DBM-5000 booklet system from Duplo. The investment is a major step forward in automation, resilience, and throughput for the company.

Mark Mugan, managing director of Direct-Ed, said: “With the Senshi, we can produce more with less. That is the way of our business – to be more efficient.” He added that the machine is easy to use, saves costs, and has transitioned the company to modern production at a time where skilled operators are becoming increasingly difficult to find.

He continued: “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.”

Duplo outlined the key benefits of the Senshi – its barcode-driven automation and touchscreen controls which reduce reliance on skilled operators and simplify training; faster job turnaround times; and its automation features which support more resilient and future ready businesses.

(L-R) Wendy Hogg, Duplo’s regional sales manager, Vicky Mugan, Direct-Ed’s director, and Mark Mugan, Direct-Ed’s managing director

The iSaddle Senshi produces up to 5050 A5 booklets per hour, or 10,100 in 2-up mode, making it suited to the demands of educational print production. The machine supports booklets up to 120 pages, accommodates A4 landscape formats, and is designed to handle a range of job types with minimal setup requirements. The system is intended for ease of use, with automated job changeovers and a PC-based graphical interface to assist operators and reduce the likelihood of error.

The investment decision was made following a visit to Duplo’s showroom. While the company initially considered the DBM-700, the Senshi was ultimately selected due to its broader feature set. The purchase was financed through Compass Business Finance.

Direct-Ed’s relationship with Duplo spans several years and has included the use of previous Duplo booklet systems. This familiarity contributed to a smoother transition to the new equipment. According to Mr Mugan, the service and support provided by Duplo were a factor in the decision-making process. “The working relationship is important. If we have a technical issue, we know it will be addressed promptly,” he said.

The Senshi is currently in daily use at Direct-Ed’s Accrington site, where the company produces up to two million personalised school exercise books per year. The business supplies both direct to schools and through trade channels. As part of its long-term plans, Direct-Ed is aiming to expand operations into a neighbouring location and achieve 20% year-on-year growth.