Route 1 Print triples its large-format finishing capacity and brings production in-house with a suite of PLASTGrommet automation solutions
Route 1 Print has announced a major restructuring of its large-format finishing workflow following a series of investments in PLASTGrommet technology. Operating from a 300,000sq ft facility in Rotherham, the company manages over 10,000 jobs weekly, with large-format products accounting for approximately 2,000 of those orders.
To address sustained growth in demand for outdoor banners and signage, the business brought previously outsourced finishing processes in-house. This transition began in September 2024 with the installation of an Evolve Air Welder and two eyelet presses utilising proprietary clear, rust-free eyelets. These were followed in May 2025 by a dedicated Finishing Station, and culminated in November 2025 with the addition of the Hybrid TexWiz integrated banner finishing platform.
The Hybrid TexWiz combines automated cutting, eyeletting, welding, and fabric sewing within a single system. This integration allows Route 1 Print to finish both PVC and polyester heras fence banners on a single machine, a move that has effectively removed previous production constraints.
Mark Young, Managing Director of Route 1 Print’s parent company, Bluetree Group, said, “Finishing is one of the biggest challenges in large-format production, so introducing more automation allows us to deliver higher quality products faster while expanding the range of solutions we can offer our customers. The TexWiz impressed us with its unmatched finishing performance and speed. It has significantly increased our capacity, allowing us to meet higher demand with ease.”
The shift toward automation has also addressed labour efficiency. Prior to the TexWiz installation, banner finishing required three operators; the company anticipates this will reduce to a single operator, allowing for better resource allocation across the 350-strong workforce. Furthermore, the use of clear eyelets ensures that banners printed on PP and PE materials remain within a single waste stream, supporting the sustainability requirements of trade customers.
Regarding the operational impact, Young added, “The improved finishing automation, particularly with the TexWiz, will allow us to nearly triple our capacity, significantly enhancing turnaround times and enabling us to take on a greater volume of work. Bringing these processes in-house has allowed us to streamline production, maintain higher quality control, and deliver a more consistent, premium product to our customers.”
The installation and training were supported by PLASTGrommet’s UK distributor, Atech. The simplified operation of the new machinery enabled the large-format team to become fully operational on the TexWiz within days of installation.
Rafa Menéndez, Head of Sales and Marketing at PLASTGrommet, said, “Route 1 Print demonstrates what can be achieved when investment in large-format finishing is prioritised alongside the latest print technology. Finishing can often be an oversight but can be the difference between staying competitive and falling behind. It has been a pleasure working with Route 1 Print alongside our UK distributors Atech on streamlining its finishing automation.”