Large-format print finishing at scale: How Route 1 Print removed bottlenecks and increased capacity with PLASTGrommet
Large-scale production demands a streamlined workflow to meet customer expectations for speed and reliability. Route 1 Print is a company that has built its operation around this requirement. As the UK’s largest trade printer, Route 1 Print operates from a 300,000sq ft facility, employs more than 350 staff, and works exclusively with print resellers as an extension of their businesses.
With more than 10,000 jobs dispatched each week, maintaining reliability and consistency is central to the operation. Large-format print accounts for 15–20% of overall output, equating to around 1,500–2,000 jobs each week spanning a wide range of applications, including posters, signage, roller banners, outdoor banners and exhibition stands.
In recent years, the business has seen sustained growth in demand for outdoor large-format print, particularly banners and signage, as organisations look for more visible ways to communicate. For smaller businesses in particular, these formats offer a practical and cost effective route to high-impact display.
In order to keep pace with this growing demand, Route 1 Print decided to take control and was seeking a solution that would enable it to bring all large-format print finishing in-house.
This led the company to PLASTGrommet, a leading manufacturer and supplier of banner and textile finishing automation solutions with a history of R&D dating back to 1990. From automatic eyelet presses and integrated banner and textile finishing systems, to media roll lifters and storage racks, PLASTGrommet’s entire portfolio has been designed to streamline and automate the banner and textile display finishing process.
The Finishing Station at Route 1 Print
Bringing large-format finishing in-house
Growing demand for large-format products, combined with a focus on finishing automation, prompted Route 1 Print to review its existing processes. Some elements of large-format finishing had previously been outsourced, and a lack of end-to-end control was a key frustration. As the business explored options to bring more of this work in-house, the team encountered PLASTGrommet’s large-format finishing automation solutions at FESPA Global Print Expo 2024.
With brand quality and performance central to this decision, PLASTGrommet’s range was a strong fit for Route 1 Print’s requirements.
“We require finishing equipment that can keep pace with fast turnaround production while consistently delivering a premium product, with no compromise on quality or reliability,” says Young.
Route 1 Print’s initial investment included the Evolve Air Welder and two eyelet presses for clear eyelets, installed in September 2024, followed by the Finishing Station in May 2025.
Reflecting on the impact of the Evolve Air Welder, Young notes that it marked a clear increase in output.
“The quality of the product it produced was much better than what we’d had in the past. It has enabled us to produce these products at scale and expand our product range. The investment has significantly increased our production capacity, freeing up resources across the business.”
Aerial view of Bluetree Group’s production facility
Operational and sustainability benefits
The addition of the eyelet presses delivered both operational and sustainability benefits.
Using PLASTGrommet’s proprietary clear eyelets enables banners printed on PP and PE materials to remain within the same waste stream, an increasingly important consideration for Route 1 Print’s customers. From a finishing perspective, the clear, rust-free eyelets also provide a clean, premium appearance, ensuring the final product meets both performance and aesthetic expectations.
In November 2025, Route 1 Print further strengthened its finishing capability with the addition of the Hybrid TexWiz integrated banner finishing platform, bringing automated cutting, eyeletting, banner welding, and fabric sewing together within a single system.
“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,” explains Young.
He adds:
“Bringing all production in-house was essential to ensure we could consistently guarantee the quality and turnaround times that our customers expect. 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 investment has massively freed up capacity, giving us greater flexibility in our production workflow.”
Aerial view of Bluetree Group’s production facility
Tripled capacity due to reduced bottlenecks
With outdoor banner production previously a bottleneck in Route 1 Print’s large-format finishing workflow, the introduction of the TexWiz has eliminated this constraint and enabled the company to produce banners more efficiently, with the added flexibility of being able to finish both PVC banners and polyester heras fence banners with the same machine. Three operators originally managed the PLASTGrommet finishing equipment, but with the installation of the TexWiz, Young anticipates this will reduce to just one operator, significantly improving efficiency and resource allocation.
Together, these investments have reshaped Route 1 Print’s large-format finishing operation, removing previous constraints and creating a more scalable, resilient workflow.
By bringing key finishing processes in-house and increasing automation, the business has improved efficiency, reduced manual intervention, and strengthened its ability to meet growing demand without compromising quality or turnaround times.
Hitting the ground running with support and training
Installation of the eyelet presses, Evolve Air Welder, and the Finishing Station was overseen by PLASTGrommet’s UK distributor, Atech, while the Hybrid TexWiz installation was managed by both PLASTGrommet and Atech, and Route 1 Print was fully operational on the TexWiz within a matter of days. On-site training ensured operators were confident using the equipment from the outset.
“The large-format team has responded extremely positively,” explains Young. “The equipment’s simplicity and efficiency have made a tangible difference to their workflow, improving both productivity and day-to-day operations. Our experience with PLASTGrommet has been excellent.” Visiting PLASTGrommet’s headquarters in Spain ahead of the TexWiz investment also gave the team greater visibility into the company’s capabilities and approach.
Support from Atech, PLASTGrommet’s UK distributor for smaller finishing equipment, also played an important role throughout the process.
Mark Young, Managing Director of Route 1 Print’s parent company Bluetree Group
From PLASTGrommet we add:
“From significantly increasing capacity and expanding its product offering to consistently meeting customer demand throughout the year, 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 for large-format print production, and we very much look forward to continuing the partnership.”
This focus on finishing automation has not only addressed immediate production challenges, but has also positioned Route 1 Print to support its customers as requirements continue to evolve.
Young concludes:
“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.”