Why Smart Card Processing for UK Retailers Cuts Manual Costs
September 17, 2025
Smart card processing for UK retailers is now a decisive factor in reducing operating costs. According to Mintel’s UK Retail Customer L...
Col-Tec Overseas
Industrial print equipment upgrades, like new collators, play a central role in safeguarding profitability. As machines age, they lead to unnecessary costs. These costs come from downtime, increasing maintenance bills, and lower output accuracy. Such inefficiencies lower return on investment (ROI) and restrict long-term growth.
Current market conditions make this challenge more acute. The British Printing Industries Federation’s (BPIF) Printing Outlook cites labour costs as the main issue. This is due to wage pressures caused by the challenge of finding skilled workers for UK printing firms. Meanwhile, the Office for National Statistics (ONS) says that energy-intensive industries’ output fell by 33.6% from 2021 to 2024. This shows how rising energy costs have severely impacted UK manufacturing. Unreliable equipment adds to these pressures, making it harder for print companies to compete.
However, upgrading to modern collators provides measurable ROI. With over 50 years of engineering experience, we continue to deliver world-leading horizontal collating systems.
Older collating machines can quietly erode profitability. Noticing warning signs early lets businesses act wisely before costs become greater than value.
When machines stop, productivity falls. The UK Government identifies downtime as a chief barrier to growth across UK manufacturing. According to Make UK, UK manufacturers face electricity prices 46% above the global average. This makes downtime for legacy collators even more costly. Businesses cannot afford wasted production hours.
Finding parts for older equipment is becoming tougher. It is common to face long lead times or to find components that are no longer available. Delays lead to longer outages and higher costs. That is why many companies are shifting to newer models or structured Lease and Rental options. These choices help them budget more predictably.
Precision is critical in print production. What happens when older machines lose their ability to feed or stack correctly? It results in wasted material, reprints, and less satisfied customers. Over time, this directly impacts ROI by increasing unit costs and reducing competitiveness.
Modern collators are designed to deliver measurable improvements in output and cost efficiency. By upgrading, businesses gain operational advantages that directly translate into more substantial ROI.
New machines reduce the time required between jobs. Operators can complete more runs each shift without adding staff. This improves margins and allows for quicker turnaround times for clients.
Touch-screen interfaces and automated controls make machines easier to run. Current BPIF Printing Outlook data shows that access to labour is one of the top three concerns for UK printers. The other two are pricing pressures and sales levels. Using equipment that requires less specialised training reduces reliance on rare skills. It also helps maintain consistent quality.
Official ONS analysis highlights that increased energy costs from 2021 to 2024 had a big impact on UK manufacturing output. Energy-intensive industries suffered notable declines. Modern collators are engineered to reduce power consumption while maintaining speed and accuracy. This lowers overheads and helps businesses align with sustainability objectives.
Our specialists also provide Bespoke Engineering to adapt machines for specific production needs. When businesses tailor equipment to fit their workflows, they improve efficiency and protect their ROI for the future.
Automation in collating equipment is a decisive factor in maintaining productivity. Businesses gain more accuracy, fewer stoppages, and consistent output by reducing manual intervention.
Key advantages include:
Our SMART Collator builds on these strengths by enabling on-demand set patterns. This meets the industry’s growing need for short-run and customised work. It gives production managers the flexibility to satisfy client expectations while maintaining efficiency.
Innovation has driven our progress for decades. It includes everything from our Signature Collators to tailored engineering solutions.
These advancements equip businesses with the tools to:
To see automation in action, explore our films and demonstrations.
Return on investment is measured not only through lower costs but also by the ability to secure and retain business.
Modern collators allow production teams to:
This flexibility strengthens competitiveness in markets where clients expect rapid response and reliability. After all, UK businesses are continuing to face increasing pressures. ONS data shows UK manufacturing output fell by 0.6% in Quarter 2 of 2024. This alone shows the pressure on manufacturers to make the most of their current production capacity. New collators address these challenges. They help reduce waste, minimise unplanned stoppages, and boost production hours.
Our team actively supports businesses by combining efficient equipment with long-term service support. We believe this helps them protect margins and plan for growth with confidence, which ultimately helps us, too.
Industrial print equipment upgrades are strategic investments that protect margins and improve efficiency. Modern collators lower downtime, keep maintenance costs in check, and provide reliable output. This enhances ROI for every production run.
With over 50 years of expertise, Col-Tec is recognised as a world leader in collating systems. We offer reliability that global print businesses rely on, from custom engineering to service support. Our installations worldwide demonstrate measurable ROI, scalability, and sustainable performance. Explore more through our blog or contact us directly.
Call +44 ( 0 ) 1425 627755 or arrange a consultation to see how our collating systems can improve efficiency and secure your competitive edge.
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