Whether it’s indoor or outdoor Signage, Vinyl Banners, XL promotional Posters or attention-grabbing Roller Banners, the Solopress Large Format department is where the big print gets done. These are products that demand scale, consistency and fast turnaround, often under tight deadlines and at serious volumes. We’re turn the spotlight on the people, equipment and processes involved in delivering some of our most visible work.
Workflow, software and speed
Large format print projects at Solopress begin long before ink meets substrate. Across the department, machines are unified by a shared workflow system, updated annually. The system allows operators to manage jobs efficiently, reduce errors and maintain an impressive on-time dispatch rate.
Recent in-house developments using AI have improved the speed of setup even further. By analysing job data and optimising operations automatically, the software helps the team spend less time preparing files and more time printing. With multiple shifts running across the day and night, these time savings add up.
Large Format: printing at scale
Once a job is prepped, it’s assigned to the press that best fits the material and size requirements. For wide roll media—used in Posters, Roller Banners and Vinyl Banners—the department relies on the Agfa Oberon RTR3300.
This roll-to-roll press handles material up to 3.3 metres wide and reproduces strong, vibrant colours on a range of flexible substrates. Its high-speed safety sensors are so sensitive that even a fly can trigger them, shutting off the press. That’s why maintaining a bug-free environment has become part of the job!
Two Agfa Anapurna Hybrid presses allow us to print directly onto both rigid and flexible media. They may be printing onto material such as Foamex, Correx or Dibond for one job, and a flexible medium like a giant sticker for the next. With widths up to 2.5 metres and the ability to switch between sheets and rolls, they allow us to offer a versatile range of large-scale products.
The HP PageWide XL 8000, on the other hand, specialises in paper products. From sharp and accurate technical documents to high-quality Posters, it prints at speeds up to 30 A1 pages per minute.
Cutting and shaping
Once printed, products are moved on to finishing. Some are cut to standard sizes, while others require more bespoke treatment. That’s where the Esko Kongsberg C44 comes in. This flatbed cutter offers precision and speed across a large 2210 x 3200mm bed, making it perfect for trimming signage, shaping display boards or producing one-off promotional items.
The Kongsberg is also instrumental in creative production. During the pandemic, the team used it to design and cut safety screens and sanitiser dispensers. It now plays a regular role in the production of custom-shaped Selfie Frames, cut-outs and bespoke signage for events, retail and hospitality.
For high-speed trimming of large volumes, the Fotoba XLD 320HS cutters take over. These automated XY cutters trim widths up to 3.2 metres and use smart sensors to self-align, keeping each cut clean and consistent across long runs.
The team that makes it happen
The technology’s up to the job, but it’s the team that keeps the department moving.
As Andrei Teaca puts it: “Every day brings something different. We never know exactly what products or quantities we’ll be working on, so no two days are the same.”
Adam Dean highlights the working culture: “The teamwork in the department is brilliant. The workload can be tough, but you’re never expected to handle it alone. Everyone pulls together to get the job done.”
Large Format Manager Matt Corstophine agrees: “It’s a rewarding department to run. At the end of a shift, you see what we’ve achieved—often things that didn’t seem possible at the start of the day.”
Looking ahead, Matt is also focused on growth: “We’re currently formulating plans to expand the department so that we can acquire more space for production, finishing and storage. That will leave us in a good position to introduce more features and products and keep pace with the growth of the business.”
Large Format, big impact
Solopress offers a wide range of large format products tailored to different environments and use cases. Whether you’re ordering Posters up to B0 or 40×60 for a high-street window, Vinyl Banners to promote an event, or custom-printed Signage on Dibond, Correx or Foamex, our in-house team produces it all.
Our biggest sellers, Roller Banners, are available in standard and premium formats, with options for double-sided print and extra-wide display. They’re easy to transport, quick to install and built to last—making them ideal for exhibitions, showrooms and public-facing promotions.
Whatever the product, every job benefits from the same commitment to quality, speed and service brought to you by the plant and the people of our Large Format Department.
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