ASC Direct expands to three AOPACK box making machines in the UK

ASC Direct, a United Kingdom producer of bespoke corrugated packaging, is now operating three AOPACK box making machines at its production facility.

The customer installed its first AOPACK BM2508-Plus in 2020. After several years of production experience with the machine, ASC Direct expanded its short-run box making capacity by ordering an additional BM2508-Pro and BM1800-Mini in 2025.

The two new machines were commissioned in March 2026 through GTS Europe, AOPACK’s sales and service partner for the UK and European corrugated packaging market.

An AOPACK after-sales manager recently visited ASC Direct to review the three machines in production, understand the customer’s current operating requirements and discuss future production needs with ASC Direct and GTS Europe.

One AOPACK Machine Led to a Three-Machine Installation

The most important part of this installation is not simply the number of machines.

ASC Direct had already been operating the BM2508-Plus since 2020 before deciding to invest in two additional AOPACK models. The repeat order followed several years of practical production experience with the original machine.

The BM2508-Pro and BM1800-Mini were added primarily to increase ASC Direct’s overall production capacity. The three AOPACK machines can produce a broad and largely similar range of corrugated box styles.

ASC Direct can allocate orders according to available machine capacity, corrugated board width, required functions and production schedules.

With three machines available, suitable orders can be processed in parallel, helping the customer reduce production waiting time and respond more efficiently to frequent short-run requirements.

Meeting the Demands of Short-Run Custom Packaging

ASC Direct manufactures bespoke corrugated boxes for a wide range of customers and applications.

Its online Box Builder allows customers to enter their required dimensions, select a box style and order custom-sized packaging in relatively small quantities.

According to GTS Europe’s published installation report, orders handled by ASC Direct’s direct-to-customer division range from 25 to 2,000 boxes. More than 90 percent of these orders are for quantities of 100 boxes or fewer.

This production profile creates several practical challenges:

• Every order may require different box dimensions.
• Production quantities can be very small.
• Operators must change quickly between different jobs.
• Board utilization must be carefully controlled.
• Setup time and manual handling must remain economical.
• The equipment must process both conventional and more complex box styles.

A flexible box making machine is therefore particularly valuable for this type of operation.

Instead of preparing dedicated tooling for every short order, the operator can enter the required dimensions and box style through the machine control system and begin production with a relatively short setup process.

Three AOPACK Models Supporting Different Production Needs

ASC Direct’s installation now includes three different AOPACK box making machine models.

BM2508-Plus

The BM2508-Plus was the customer’s first AOPACK machine and has been in production since 2020.

Its continued operation provided ASC Direct with several years of experience using AOPACK technology for customized and short-run corrugated box production.

The original machine remains part of the customer’s daily production setup and provides an established foundation for the expanded three-machine installation.

BM2508-Pro

The BM2508-Pro adds further production capacity and is equipped with cold gluing, QR code scanning and glue flap crushing functions. These functions allow ASC Direct to complete more production steps within one coordinated box making workflow.

The machine is designed to combine essential box converting processes within a coordinated workflow, helping operators move efficiently between different box dimensions and production orders.

By adding a second machine within the 2500 mm class, ASC Direct can distribute suitable jobs between the BM2508-Plus and BM2508-Pro instead of depending on a single production line.

BM1800-Mini

The BM1800-Mini was also purchased to increase production capacity and is equipped with cold gluing and QR code scanning. It processes narrower corrugated sheets than the BM2508-Pro, but its compact footprint allows ASC Direct to add capacity while using less factory floor space.

The BM1800-Mini can produce many of the same corrugated box styles as the two wider machines. Suitable orders can therefore be assigned according to board width, required functions, machine availability and delivery schedule.

It is particularly suitable for short-run e-commerce packaging, smaller cartons, trays, wraps and more complex packaging structures.

The BM1800-Mini allows ASC Direct to process smaller jobs on a machine designed for that size range, rather than occupying a wider machine that may be more suitable for larger orders.

This helps the customer organize production according to actual box dimensions and order requirements.

Streamlining Corrugated Box Production

AOPACK box making machines are designed to combine key corrugated converting operations into an integrated production process.

Depending on the selected model, machine configuration and box design, the workflow can include:

Slitting/ Creasing/Slotting/Horizontal cutting/Customized shape cutting/Optional gluing/Optional printing

The ability to process multiple operations through one programmable system is especially useful for short-run production, where frequent order changes make conventional tooling and multi-machine workflows less economical.

GTS Europe reported that the Boxstar production workflow enabled ASC Direct to move away from some of the inefficiencies associated with its previous rotary slitter process.

The new production arrangement helps reduce unnecessary movement between separate converting stages and gives operators a more direct workflow from corrugated sheet to finished box blank.

AOPACK After-Sales Team Visits the Customer

AOPACK’s relationship with a customer continues after installation and commissioning.

During the recent visit to ASC Direct, an AOPACK after-sales manager reviewed the operation of the BM2508-Plus, BM2508-Pro and BM1800-Mini in the customer’s actual production environment.

The visit focused on:

• Current machine utilization
• Operator experience
• Routine maintenance
• Production requirements
• Different box applications
• Future equipment and service needs

The accompanying video shows the machines operating inside ASC Direct’s corrugated packaging facility and provides a practical view of the customer’s expanded production setup.

For AOPACK, customer visits provide valuable feedback about how different machine models perform together in daily production. This information also supports future product development, operator training and after-sales service.

Repeat Investment Based on Real Production Experience

The ASC Direct installation represents more than a new equipment delivery.

The customer first introduced an AOPACK BM2508-Plus into production in 2020. After several years of operating the machine, ASC Direct chose to expand its installation with two additional AOPACK models.

The resulting production setup now includes: One BM2508-Plus; One BM2508-Pro; One BM1800-Mini

Together, the three machines provide additional production capacity for standard cases, bespoke cartons, e-commerce boxes and other customized corrugated packaging formats.

This case demonstrates how a customer can begin with one AOPACK box making machine, gain several years of real production experience and then expand to a coordinated multi-machine setup with additional capacity and automation functions.

Explore AOPACK Box Making Machines

AOPACK provides box making machine solutions for short-run, customized and on-demand corrugated packaging production.

Different models are available for smaller-format boxes, standard corrugated cases, wide sheets, heavy-duty board, fanfold material and integrated digital printing applications.

Explore AOPACK box making machines

Contact AOPACK to discuss your corrugated board specifications, required box styles, production volume and optional machine functions.

Request a Box Making Machine Consultation

This article was originally published by AOPACK.