Why Industrial Print Equipment Upgrades Improve ROI
September 26, 2025
Industrial print equipment upgrades, like new collators, play a central role in safeguarding profitability. As machines age, they lead ...
Col-Tec Overseas
A custom collator setup delivers specialised functions for UK production. It fulfils the needs for precise material handling, unique sheet formats, and total line integration. Off-the-shelf systems often create operational constraints, leading to bottlenecks, misfeeds, and time-consuming adjustments.
In fields like print, packaging, and pharmaceuticals, the demand for flexible, fast systems is increasing. The UK Innovation Report 2024 shows how important innovation is in manufacturing. It states, “sectoral and regional data [are] essential to understanding the drivers of national performance,” especially in high-value industrial applications. A custom collator setup directly addresses this need. It increases control, reduces downtime, and meets the exact technical and space needs of your facility.
This article explains five key benefits of selecting a custom-built collator. It draws on over 50 years of expertise in delivering precision systems to clients in the UK and globally.
Standardised collators are not usually suitable for production environments. They struggle with textured, coated, or non-paper materials. These systems generally need manual tweaks or compromises. This can lead to misfeeds, damage to stock, and wear on the machines.
Custom collator setups allow for precise configuration across the whole handling process:
Our experts design collators for specific applications in packaging, pharmaceuticals, and education. In fact, many have been built to ensure accurate feed and alignment. If needed, systems can have barcode verification or ultrasonic sensors to ensure quality control at all times.
Visit our bespoke engineering page to learn more about how we build to exact substrate specifications.
Does your production team work with non-standard paper sizes or variable set orders? If so, you might encounter unnecessary downtime with generic collators. Adjustments can be tedious and waste time. They often need you to repeat tasks to control sheet size, orientation, or job sequencing. Over time, these delays affect throughput, consistency, and operational costs.
A custom collator setup removes those constraints.
Each unit is designed to accommodate your specific format. No matter whether you require A4, A3, long sheets, or a combination across multiple feeders. The machine’s logic and design match your layout, speed, and sequencing needs. This alignment supports both upstream and downstream processes.
Our systems are developed through close technical consultation. You can build your own collator and adjust the feeder type, number, spacing, and sequencing to fit your floor plan and material profile. This aims to reduce changeovers and help maintain continuous production for a broader range of runs.
Production environments depend on efficiency across all systems, including feeding, stacking, and wrapping. When standard collators work alone, they can cause bottlenecks. This often requires manual help to connect the processes.
Custom-built collators are engineered to work as part of your complete finishing workflow. Does your setup include glueing stations, wrapping lines, stitchers, or film units? If so, custom integration is designed from the outset to maintain speed, accuracy, and sequence control.
Our custom engineering service makes sure all parts fit your exact production needs. This is true whether you are adding to a packaging line, mailing process, or film wrapping system.
In high-volume environments, speed is only valuable if it is matched by accuracy. Off-the-shelf collators can struggle when pushed too hard. This may cause more misfeeds, alignment problems, or stoppages, which can hurt downstream output.
Custom-built systems are specified to match your production targets, including:
Our machines are designed to keep output quality high even at high speeds. They lower error rates, protect sensitive materials, and maintain order in large quantities.
Each build can have active sheet monitoring, trays for faulty sets, and systems for automated realignment. These safeguards reduce the need for post-run inspection or rework. According to the High Value Manufacturing Catapult’s 2050 Vision for Automation and Robotics, the UK is the only G7 country with a robot density lower than the global average. This indicates an urgent need for investment in high-performance automation. Investing now will help the UK close the productivity gap and stay competitive.
To see how throughput is maintained without losing quality, visit our films archive. It features video walkthroughs of completed installations.
Long-term performance relies not only on machinery but on the availability of expert technical support. For production teams in the UK, having local engineering access can lead to quick resolutions or extended periods of downtime.
Our engineers design, build, install, and maintain every system from our facility in Hampshire. This ensures fast responses on-site, training, and support during the machine’s lifecycle.
The Make UK Manufacturing Outlook Q4 2024 report shows that rising costs and supply chain disruptions have sharply reduced business confidence. This points to a need for stable local support and investment in systems that boost productivity. With our in-house engineering and a UK supply chain, clients benefit from reliable operations and support.
To explore lifecycle service and maintenance options in more detail, visit our service page.
A custom collator setup assists UK manufacturers, printers, and packagers with their challenges. This is especially true for those dealing with high volumes or complex materials. When you choose a system that meets your exact needs, you remove the limits of standard equipment. This also gives you more control over your production line.
Col-Tec’s custom solutions offer great reliability, accuracy, and fit right into your current workflow. Our engineering support in the UK keeps your collator fully optimised throughout its life. This gives you confidence in its long-term performance. If your current collator is limiting your production, Col-Tec’s team can create a custom machine for your needs.
Call +44 ( 0 ) 1425 627755, request a consultation or send your material samples to begin the specification process.
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