Zell-Em Branding bolsters production with new ColorJet Vulcan Hybrid 3202 printer from QPS

Print Solutions

Lancashire print, signage and workwear business Zell-Em Branding has reported a considerable increase in output speeds since installing a ColorJet Vulcan Hybrid 3202 from Quality Print Services (QPS), enabling the company to take on larger projects and strengthen its large format offering.

Zell-Em's heritage spans well over a century, bringing together the expertise of several long established businesses under a single brand. While the company itself was founded in Blackpool in 1946, its roots stretch back to 1890 through Granthams Signs & Graphics, one of the north west's most established signage specialists.

The wider business also includes Beaver International, which has supplied branded workwear since 1980, and MacPrint UK, a garment screen printing specialist with more than 30 years of industry experience.

In 2025, the business unified its four divisions under the Zell-Em brand, creating a stronger, more cohesive identity while preserving the expertise, reputation and heritage of each individual business.

Today, the company continues to invest in the latest print technology, product innovation and its digital presence, ensuring it remains well positioned to meet changing customer demands and compete in an evolving marketplace.

It was this philosophy that led Zell-Em to invest in the ColorJet Vulcan Hybrid 3202. Steve Cartmell, operations manager, said the company was looking to replace a machine that was reaching the end of its operational life. However, rather than replacing it with a similar mode, the company saw it as an opportunity to increase its capabilities and futureproof part of the business.

‘We didn’t want a like for like replacement,’ Steve said. ‘We wanted a machine that would allow us to handle greater volumes, improve productivity, create new opportunities and remove the need to outsource jobs that were too large for our old printer. The Vulcan ticked all those boxes.

‘Compared to our previous equipment, the Vulcan offers significantly higher production speeds, a much larger print width and improved print quality across a wide variety of substrates.’

The ColorJet Vulcan Hybrid is a 3.2 metre UV-LED hybrid printer designed to handle both rigid and roll to roll media on a single platform. Configured with Ricoh Gen6 printheads and CMYK plus white ink, the device can print at speeds of up to 91 square metres per hour, supports rigid media as thick as 35 mm and produces output at resolutions of up to 2400 dpi. Other features include dual UV-LED curing and an Onyx Thrive RIP workflow.

Despite having only been in place a matter of months, Steve said the new ColorJet printer has already become a key part of the company’s large format department and is used across a wide range of applications.

‘The most obvious benefit has been the dramatic increase in productivity,’ he said. ‘One recent project consisting of 10 mesh banners measuring 10 x 1.85 metres would have taken about 14 hours to produce on our previous machine when it was operating at its best. The Vulcan completed the same job in around four and a half hours, including a roll change.

‘Beyond speed, output quality has improved markedly, with better colour consistency, sharper images and excellent curing performance across all substrates. Reprints have become extremely rare, reducing waste and helping improve overall efficiency.

‘The additional capacity has enabled us to take on more work while maintaining competitive lead times and pricing. In particular, we have seen strong growth in roller and large format banners.

‘One of our existing trade customers has increased their monthly spend with us by approximately 80% compared with the same period in the previous year. They have always valued our service and quality, but the additional capacity and faster turnaround times have allowed us to compete much more effectively on larger projects that we may previously have struggled to win.

‘The productivity gains have exceeded our expectations. We are producing work faster, improving quality, reducing waste and still have significant spare capacity available. It has given us a genuine competitive advantage.’

Looking ahead, Steve said Zell-Em sees the ColorJet Vulcan as a platform for growth, with the machine having strengthened its position in markets it already serves while also opening doors to new opportunities in areas such as retail graphics, exhibition displays, construction signage and billboard printing.

‘The increased print width and productivity mean we can now confidently target larger format projects, while the flexibility of the hybrid platform allows us to diversify into applications that we may not previously have promoted as heavily,’ he said.

‘Another important factor is scalability. The Vulcan platform can be upgraded with additional printheads in the future, providing the option to increase output speeds by up to 50% or even 100% if demand requires it. That gives us confidence that the machine can continue to support our expansion for many years to come.

‘This wasn't simply an investment for today. It gives us the flexibility to expand into new applications, the throughput to meet increasing demand and the scalability to support the business for years to come.’

Steve also took the opportunity to pay tribute to the service and support of QPS, not just during the investment process but also with delivery, installation, training and ongoing aftercare.

‘We have worked with Chris Bailey, QPS managing director, and the team previously and have always found them honest, knowledgeable and straightforward in their approach,’ Steve said. ‘We never felt under pressure during the decision making process and had confidence that the support behind the machine would be just as important as the machine itself.

‘The installation was carefully planned because the machine could not be brought into the building through our existing access points. Following a site survey by QPS, we installed a new roller shutter door ahead of delivery. The installation team handled the process professionally and efficiently, ensuring the machine was operational with minimal disruption.

‘Training was thorough and comprehensive, and we particularly appreciated the follow up visit a week later to ensure everything was running smoothly and to provide any additional guidance required.

‘The support we have received from QPS has been second to none. The machine has delivered everything we hoped for in terms of quality, speed and versatility, and it is reassuring to know that whenever we need advice or assistance, the QPS team is always there to help. We wouldn’t hesitate to recommend them.’