6th October 2009
Mainlines September 2009 Brochure features 2 new ranges. 4 sizes are launched in the ‘ECO’ 450micron grey, whilst the ‘ECO-MEDIA’ 600micron brown range focuses in the CD & DVD market. Both ranges are produced from 98-100% post-consumer waste paper/board to encourage customers to follow Mainlines path to environmental improvement. ECO-friendly and ECOnomically priced.
FREE 2-3 day delivery now applies for all orders over £100. Click here to download the brochure
15th June 2009
Mainline are featured in the June issue of Print Media Management Magazine : "Creativity and envelopes go hand-in-hand at Mainline Flatpacks, where eye-catching and innovative cardboard mailers are the speciality."
Please click on the following link to read the full article (Mainline article PMM)
30th April 2009
Mass produced for the Theme Park market, Mainline introduced this range of glued slip-in photofolders available in either landscape or portrait format to hold 6x4", 7x5", 8x6" and 10x8" prints. The range is produced on a 380gsm black dyed material.
Please click on the following link for further information (Mainline slip-ins flier)
5th January 2009
Mainline invest over £100,000 in film applicator upgrades to improve efficiency of its PECOpak® brand of retention packaging. Mainline are the only European manufacturer capable of producing the lithographic offset printed retention packaging with peel and seal closure, thus ensuring fastest leadtimes and best price.
1st October 2008
Further to Mainline's 25 years trading as a family business in the supply of Photo packaging to the major processors, we have launched a new range of photo mounts available to all.
The Uniqueness of Mainline photo strut mounts are:
· Stiff material yet lightweight to save postage costs
· No unsightly nicks or notches
2nd July 2008
Mainline celebrate its 25th year of trading and remember when it all started in 1983. The company remains a proudly independent family business and looks forward to the next 25 years.
You can follow Mainlines timeline by looking through the older articles listed at the bottom of the page...
1st July 2008
A B1 Computer to Plate (CTP) processless plate system has been installed at Mainline to replace its film processing system. This has elimated all chemistry required for producing plates and greatly reduced the energy and water requirements of this process. CTP is yet another step towards environmental improvement at Mainline whilst customers enjoy improved print quality and faster output of plates.
1st June 2008
Mainline have purchased a wide format Apollo Inkjet UV digital printing press; voted number 1 at the sign and digital show. This has widened Mainlines print capabilities to:
Printing quality: apparent 720 – 1200dpi
Size: up to 1600mm wide x as long as you want
Thickness: up to 76mm thick (yes we could technically print a house brick!)
Substrate : any flat surface
The technology is Digital inkjet UV printing, so each sheet could be different, and is UV cured so colour is guaranteed outdoors for 2 years, and will not run. Mainline guarantee printed displays to be weatherproof in the Sahara for 12 months.
1st May 2008
Mainline express their thanks to its customers for visiting their stand at the ‘International Direct Marketing Fair 2008’. The exhibition was an ideal platform for the company to demonstrate its packaging capabilities to Marketing & Mail-Order clients. Mainline promise the “goody bag” will be back by popular demand.
1st April 2008
The Soil Association awarded Mainline with FSC (Forestry Stewardship council) for chain of custody of paper/board which has been sourced from sustainable forests according to strict environmental, social and economic standards.
2nd February 2008
Through continuous research and development of machinery, Mainline have designed a cost effective and environmentally friendly packaging system, the PECOPAK®. This registered trademark of Mainline is so named after its two constituent parts : Flexible Polythene (PE) applied to Corrugated cardboard (CO) .
Clients slide various size items under the film and upon folding the cardboard back on itself, the polythene stretches to hold the item securely without any movement. This solution eradicates the need for packing materials, is fully recyclable, and minimises the possibility of damages through the mail.
1st February 2008
Following the purchase in October 2006 of a neighbouring 30,000sq ft warehouse, Mainline have completed its refurbishments to the finishing area and installed a 2100 pallet racking system, purposefully designed to requirements.
This means Mainline now produce all their goods from 60,000sq ft. premises in Huntingdon. The new machinery layout and storage locations allow for a far more efficient work flow, reducing handling of goods by 50%.
2nd January 2008
With the addition of another 2.75m crash-lock unit to our Bobst Alpina, it now measures 33metres in length, making it the second largest cartonboard gluing machine in the UK
1st January 2008
Chairman of Mainline Flatpacks Ltd, Roger Lill presented the award for ‘Best Corporate Stock Calendar 2008’ at the National Business Calendar Awards at the London College of Communications.
Mainline continue to support the awards as the major supplier of Calendar envelopes in Europe.
17th August 2007
Mainline are exploring FSC sustainable Forestry Certification as a further avenue to reduce carbon footprint and landfill waste. The company already uses vegetable based inks, corn cellulose films, post-consumer recycled cardboards and works to ISO14001 but feels FSC puts into practice new methods of prolonging the life of our planet.
26th July 2007
Mainline have been awarded certification to ISO 14001 by URS. The new environmental management system is in addition to the ISO 9001 quality system that the company has been using since 1996. Mainline believe it is important that all businesses take the time and effort to be environmentally responsible and to actively reduce their impact on the environment. Please contact us for further information with regards to fully recycled packaging.
1st April 2007
Thanks to a magnificent effort by the sales department, the company achieved its record financial year. In addition to securing numerous new contracts, Mainline managed to achieve growth to its existing client base through product development. The production department excelled to maintain a 99.6% “on-time” delivery status through this busy year.
9th January 2007
Despite todays pressures on UK manufacturers to compete with the far east, Mainline have proved that their efficiencies in manufacture are too strong for manufacturers in China. The customer for this particular project was amazed with the contradiction to modern beliefs. It was also made clear by Mainline that the so-called benchmark supplier could also not meet quality and service demands.
20th November 2006
Mainline now accept VISA / Visa Electron / Maestro / Switch / Solo debit & credit card payments to ensure instant release of ordered goods at no additional charge.
13th November 2006
Board price increases of between 5% and 8% are being rolled out across all the board mills as a result of increasing energy costs, transport costs and raw material costs. This increase is being introduced as vital for the survival of the European board making industry. This will affect the costs of bespoke manufacture however Mainline Flatpacks Ltd will absorb this increase for its envelope stock ranges for 6 months and review on 1st July.
(Effective January 1st 2007)
1st November 2006
Mainline’s new price list is published showing reduction in prices for LP mailers and C3 sizes.
Prices have now either been held or reduced for all stock lines since January 2006 thanks to efficiencies of our BOBST gluing technology – see October 2005 news.
30th October 2006
Mainline record the best month sales in the companys 24 year history. October 2006 Sales reached £775,768.
26th October 2006
Mainline secure property purchase of nextdoor 30,000 sqft warehouse facility and to purchase our existing 30,000 sqft leased buildings. This increases capacity to 60,000 sqft.
23rd September 2006
Mainlines company mascot ‘Wally the Wallet’ was entered for the Huntingdon Racecourse Mascot race. Our staff helped us raise £161 for ‘The Childrens Trust’.
1st July 2006
Mainline prepares for Royal Mails Pricing in Proportion (PiP) with the stocking of the 2 compatible envelope sizes. Both stock lines prove hugely successful:
[see pictures left & contact us for samples and prices]
1st June 2006
Mainline introduce a range of stock sizes of 17 Boardback envelopes to compliment the 210gsm (280micron) and 385gsm (500micron) cardboard envelope ranges.
[see pictures left & contact us for samples and prices]
1st April 2006
Mainline Flatpacks Ltd steps into the European market by appointing a dedicated export sales executive fluent in German, Dutch, French, Spanish and Italian. See the launch of our multi lingual website in December 2006!!!
1st March 2006
It features a peel & seal closure with reverse score tear strip opening and a tuck flap for re-use. The range is stocked in 4 sizes, all from 500micron WHITE cardboard:
PEC5 PiP 164 x 239mm (compliant with Royal Mail ‘Letter’ tariff)
PEB4 PiP 249 x 352mm (compliant with Royal Mail ‘Large Letter’ tariff)
PEC3 330 x 458mm
PEC2 626 x 451mm
[Download PDF & contact us for samples and prices]
1st October 2005
A tremendously successful open day was the official launch for the installation of the new Swiss gluing machine, the ‘Bobst Alpina Giro 110.’ The machine, with applicators from America, applies hot melt peel & seal, double sided tape peel&seal, red ripstrip, window patch and sequential numbering AND gluing all in one pass at world class speeds, typically 180 mpm.
1st July 2004
Stock envelope range quadruples
2004
Having offered only 27 stock items in 2002, Mainline increase their range of stock items to 140 with the inclusion of the ‘210gsm Litewhite range.’
Mainlines competitors cease trading
2003
Mainline survive the dotcom decline in demand for CD pockets unlike its two UK competitors. The company is producing APS photo wallets on a large scale for Kodak. Mainline acquire the cardboard envelope brand names ‘Petavelop’ ‘Petaseal’ & ‘Petamaila.’
New machinery
2000
Mainline invest in a 2nd Komori 5 colour B1 press with extended coating unit. Parts for both machines are interchangeable and jobs can be moved from 1 machine to another with minimum disruption. The company also purchases a new ‘Vega Sirio’ which is one of a new generation of fast gluing machines capable of handling a wide variety of formats. Mainline grow from £3.5m to £4.5m thanks to the growing dotcom market for which Mainline supplied CD pockets to : Freeserve, BT, Psion, AOL, Netscape, Yell …..
Window patched acquired
1999
Mainline purchase an ‘Accent’ window patcher to enable all styles to be manufactured ‘in-house.’ Print department running 24 hours/day to manage high demand.
10,000sq ft additional warehouse
1998
Due to expansion, Mainline overflow to into neighbouring unit to store finished envelope stocks. Business now operating over 30,000sq ft. Packaging waste regulations come into force.
The Lill family in full ownership
1997
Howard Clark sells his share of the business to Roger & Jane Lill. Their sons Barry & Fred begin working in the factory between school terms.
CAD/CAM installed and in-house pre-press
1996
Having made samples by hand for 13 years, the company moves forward with a computer generated CAD/CAM design package. In the same year graphic design and plate-making comes ‘in-house.’
New press / Peel & Seal / BS5750
1994
Having visited Komori in Japan, Managing Director Roger Lill invests in a new ‘Komori’ 5 colour B1 printing press. 1994 also saw Mainline introduction of peel & seal cardboard envelopes to the market and the company gained accreditation of BS 5750 quality management systems (ISO9000). 39 staff with turnover exceeding £2,000,000
Computerised estimating installed
1992
With 4 computers, the company installs a ‘Cabbell’ estimating system. The Roland press is replaced with a reconditioned ‘Crabtree Sovereign’ 5 colour size 6 press.
Mainline moves to Huntingdon
1990
Relocation 4 miles away to Glebe Road, Huntingdon provides 20,000 sq ft facility for the company. The familiar blue and red M logo is launched.
First computer purchase
1988
The finance department are allocated budget to invest in the company’s first ever computer. Company now employs 32 staff with turnover of £804,704 after 5 years trading and current 10,500 sq ft premises is at full capacity.
Self Seal machine purchase
1987
A reconditioned ‘Lerner’ latex machine is purchased to capitalise on a new market for self seal cardboard envelopes.
First brochure
1986
Mainline design & print its first brochure titled “You’ve gotta pick a pocket – or two.”
Acquire 4 colour press
1985
Mainline purchase a reconditioned Roland 4 colour size 6 press and expand to next door additional staff (now 23 staff in 7,000 sq ft premises)
24 hour/day operation
1984
15 employees now providing capacity of 400,000 envelopes per week.
Mainline Established
1983
The company was founded in April 1983 by Roger Lill and Howard Clark with an investment of £3,500 each. The purpose was to be a lively manufacturer of unprinted tuck flap cardboard envelopes to fill a gap in the envelope market. The 3,500sq ft factory was on Edison Road, St.Ives Cambridgeshire employing 8 staff to man the 3 finishing machines with capacity of 100,000 envelopes per week.
