Shropshire, UK-based Dairi-Pak has installed a new MC CUIR flexo-die cutter, reshaping how the business produces printed die-cuts, addressing workflow challenges and future proofing operations.
Founded in 1988, Dairi-Pak supplies corrugated packaging to the food, drink, and dairy sectors. The business operates in a 30,000 sq ft facility, employs 50 people, and reports annual turnover of approximately £11m following its 2025 acquisition of Peter Marsh Packaging.
Prior to the new CUIR installation, Dairi-Pak relied on an older flatbed die-cutter; despite its age, the machine remained dependable, offering repeat-job setup times of around five minutes and low origination costs with minimal tooling and no stripping or lead-edge knock-off requirements. This supported a highly flexible, responsive production model.
Print Demand Shifts Production Priorities
Over the years, customer demand for printed die-cuts increased across short and long run lengths, shifting production priorities toward printing and exposing inefficiencies in the existing workflow. Under the existing setup, printing and die-cutting were separate processes. Sheets were printed, palletised, strapped, and moved across the warehouse before being converted on the die-cutter. Once cut, they were palletised and strapped again for dispatch.
This double handling added time, labour, and potential for waste, with board movement sometimes taking up to 30 minutes. Flexo lines were tied up producing printed sheets rather than finished cases, and lead times increased as workloads became more complex. Tim Gray, owner of the company, knew it was time to evaluate a new solution to power the next chapter of Dairi-Pak’s success.
Inline Printing and Die-Cutting
When evaluating solutions, Dairi-Pak’s requirement was clear: one machine to produce printed die-cuts in a single pass, without increasing footprint or origination costs, or sacrificing setup speed across varying runs.
That requirement led the team at GTS Europe to introduce the Cuir MC, being the UK sales agent. Manufactured in France by CUIR Corrugated Machinery, the compact MC combines two-colour printing, inline flatbed die-cutting, vacuum stripping, and multi-out delivery within a single frame. Arran Sethi of GTS Europe knew the MC would be the perfect solution for Dairi-Pak’s operations.
Perfect Machine for Sheet Plants
“It was out with the old and in with the new,” said Tim Gray. “We removed outdated machinery and installed Cuir’s cutting-edge technology to future-proof our operations.”
The MC CUIR meets all requirements for high-quality, inline sheet printing and die cutting, combining fast setup, production speeds up to 3,000 sph, and a compact footprint of approximately 11m from feeder to delivery.
A fully servo-driven vacuum feeder handles board thicknesses from 1 to 7mm and sheet sizes from 550 x 500mm up to 1300 x 1700mm, including warped board. Printing units are equipped with Absolute Engineering carbon-fibre ink chambers, Pamarco anilox rolls, and peristaltic ink pumps for stable ink control and efficient colour management. While belts, vacuum, and sensors maintain board stability and accurate cut-to-print registration through the machine.
The flatbed die-cutting process uses tooling with integrated air pods that secure the sheet during cutting and ejecting waste into a vacuum system above the die. This eliminates stripping tools, lead-edge knock-off systems, or breakers, keeping origination costs low while maintaining clean, nick-free, multi-out production.
Setup times are a major benefit with repeat die-cut jobs prepared offline using a two-cart system and set in under five minutes. Stored job recipes significantly reduce make-ready time for printed work.
Fast Installation
Installed during the 2025 festive season shutdown by CUIR and GTS Engineers, the MC has significantly improved turnaround times and efficiency at Dairi-Pak already. The project was completed with minimal disruption and managed by Dairi-Pak’s newly promoted Production Director, Luke Williams, following his completion of the UK Sheet Plant Association Emerging Leaders Programme.
Printed die-cuts are now produced in a single pass, eliminating double palletising, strapping, and internal transport. Casemakers remain dedicated to case production, while both high and low volume work runs faster with improved multi-out efficiency. Overall job turnaround times reduced by more than half.
“These significant upgrades boost capacity, enhance quality, and reinforce Dairi-Pak’s commitment to delivering packaging excellence to our customers,” concludes Tim Gray. “In my view, the Cuir MC is the perfect sheet plant machine.”
For Dairi-Pak, the investment reflects a long-term commitment to operational resilience, pairing a high-quality Cuir solution with a production approach designed to meet evolving customer demands for many years to come.
