Route 1 Print invests in ABG DigiLase Duo

Route 1 Print, one of the largest online trade printers in the UK, has invested in a new ABG DigiLase Duo and Dual Bar DigiJet to meet the demands of the growing stickers and labels market.

Based in Rotherham and operating from a 300,000sqft manufacturing facility, the latest addition marks the investment in a wider £2m project delivered over the past 12 months, which has also included the installation of an ABG Digicon Lite and HP Indigo technology.

The addition of the DigiLase Duo, alongside the Dual Bar DigiJet and thermal laminator module, has expanded Route 1 Print’s sticker and label capabilities. At the heart of the line, the DigiLase Duo features two independent 400w laser heads, delivering faster cutting speeds, greater resilience and the precision required for intricate custom shapes, decal-style products and shorter-run sticker work without the need for traditional tooling.

With full laser hardware redundancy, the system has been designed to support increased throughput while helping maintain consistent production reliability.

The company reported that the investment opens up a wider choice of premium stickers and labels for customers available through Route 1 Print’s online ordering platform. The Dual Bar DigiJet enables digital embellishment, including spot varnish, foiling and tactile effects, allowing high-impact finishes such as spot UV-style detailing and foil to be applied to the same label in a single pass.

This gives customers more creative freedom when producing standout branded labels, promotional stickers, product packaging and premium decal products, without the cost or lead time traditionally associated with specialist finishing tools.

Jack Parks, head of Route 1 Print, said: 'Stickers and labels have become a major area of growth for Route 1 Print, and this investment gives our customers even more opportunity to go after more premium label work across sectors such as food and drink, cosmetics, pharmaceuticals and more.

'For resellers, it means they can offer their clients short-run, high-quality labels with fast turnarounds and competitive trade pricing, giving them the chance to build in a strong margin. Just as importantly, they can do it all through our simple online platform, without relying on long-winded off-line quoting and proofing processes.

'With free online proofing, our AI-powered artwork tools, a growing range of premium finishes and additional machine-applied reel specifications, we’re making it easier for our customers to target clients with more specific label needs, including those with detailed packaging and application requirements.' 

The addition of the thermal laminator module provides another layer of flexibility to Route 1 Print’s sticker and label production. By bringing thermal lamination directly into the workflow, the business can produce labels with improved durability, added protection and a more premium finish, all while keeping production moving efficiently.

With digital laser cutting, embellishment and lamination now working together in one advanced finishing setup, Route 1 Print has strengthened its ability to produce more complex sticker and label work at scale. It gives the company a stronger platform to keep expanding its online range and bring more specialist label options to market for print resellers.

Mark Norman, ABG’s technical director, said: 'The DigiLase Duo is the result of pushing the boundaries of what’s possible with digital laser cutting and in-house software development.

'By introducing dual independent lasers, we’ve been able to deliver enhanced speed, flexibility and reliability, while also helping to minimize waste. It’s a significant step forward in digital finishing technology.'

The DigiLase Duo also supports Route 1 Print’s sustainability objectives and those of its customers. Through ABG’s advanced ABG Connect workflow, job changes are optimized to minimize waste, reduce material loss and support leaner, more environmentally conscious production.

Mark Young, managing director of Route 1 Print, said: 'ABG has been a fantastic partner throughout this investment.

'From the early planning stages through to installation and ongoing support, their team has worked closely with us to ensure the new DigiLase Duo and Dual Bar DigiJet setup was delivered smoothly and integrated effectively into our production environment.

'Their understanding of high-volume label production, combined with their technical expertise and responsiveness, has given us real confidence throughout the process.'

The investment follows a sustained period of growth and innovation within Route 1 Print’s stickers and labels category. Over the last 12 months, the company has expanded its range to include labels supplied on reels, decals, custom shapes and sizes and new materials such as transparent and silver metallic polypropylene.

Route 1 Print has also introduced specialist finishes, including new Grit Touch lamination, spot UV and foil, as well as additional specifications for machine-applied reels, including winding direction, leading edge and gap between labels, allowing its customers to better support clients in industries with more specific packaging and label application requirements.

Alongside these product developments, Route 1 Print has enhanced the customer experience by launching an AI-powered Custom Shape Proofing Tool. This removes the need for resellers to request cutter files from their customers, helping save time, reduce costs and cut down on back-and-forth.

The company has also redesigned its stickers and labels ordering journey and produced a fully unbranded sample pack, created specifically to help print resellers win new business.

The latest investment aligns with Route 1 Print’s ongoing strategy to expand production capabilities. According to the company, by providing print resellers with more unique, bespoke sticker and label options at low trade prices, it is helping customers grow their product range, increase margins and stay competitive in a demanding market.