When we began discussing the need for a new manufacturing facility back in 2022, it became clear that this wasn’t just a long-term ambition for the business – it was a pressing requirement.
Compounded by unpredictable supply chains and rising customer expectations our production capabilities were at risk of becoming stretched. With an obvious eye on our ability to continue to grow and expand, the decision to relocate was a strategic necessity.
We were also seeing an uplift in physically larger automation projects, which were occupying increasingly significant areas of our assembly space. These large projects could make the production floor tight, and we were at risk of a knock-on effect for spares, stocking components, and moving efficiently from one process to the next. We knew something had to change before we reached critical mass. After identifying the need to move, we began looking for new premises. That was no easy task.
We’re in a bit of a “Goldilocks zone” when it comes to size: too big for standard industrial units, too small for full-scale distribution centres. Eventually, we found a location slightly larger than we had planned, but it turned out to be exactly what we needed. The extra space allowed us to bring machining in-house, something I’d been looking at for quite a while as machined parts were typically outsourced, adding to production times.
While we have always been able to handle assembly and integration internally, , with our own CNC mill and lathe on-site, we’ve dramatically reduced lead times. A part that could take three to four weeks externally can now be turned around in just a few days. Not only is this more efficient, but it’s also more cost-effective and the result is a better return on investment for our customers.
Having our own machining capability has also improved flexibility particularly when it comes to R&D. If a development part needs tweaking, we don’t have to wait. We can test, adjust, and re-run it ourselves, quickly and efficiently.
The benefits extend beyond manufacturing. Our service and repair capacity has expanded significantly, thanks to a dedicated RMA area. Now, we’ve got the physical separation and storage needed to manage customer returns more effectively, improving traceability and turnaround time, which helps us to showcase our status as a Zebra Premier Print Engine Repair Specialist.
Our new development areas have also unlocked possibilities that were previously a challenge. Whether it’s building prototypes, stress testing systems – like our new linerless print and apply machines – or preparing for the integration of larger equipment for a full end of line automation system, we have the space to design, build, and test under one roof.
We’ve now set up a dedicated visitor centre to demo our solutions, offering visitors the chance to experience them in action. Which leads on to improved customer engagement. The new visitor centre includes a dedicated demonstration space, a meeting area, and a viewing gallery overlooking the production floor.
It all adds up to a far more immersive and transparent experience, giving customers full visibility of their project’s progress. With our project management software, customers can receive visual updates on timelines and milestones, adding another layer of confidence to their automation journey with us.
The move has also enabled us to grow the team. We would have found it difficult to add more engineers at the old site. Now, we’re able to hire for new skills, from machinists to development engineers, and support their integration really well. In fact, our in-house machinist joined us before the machines were even installed. That early involvement helped him shape the spec and setup, making everything smoother from day one.
This growth isn’t just about headcount. It’s about capability. With greater capacity, we’re better positioned to offer new services, explore new technologies, and build even better solutions. We’re also creating more resilient, future-ready systems, ones that deliver measurable value and a stronger ROI – that’s a rarity in a world or rising costs!
Our industry has changed rapidly, and our new facility has enabled us to adapt with it, offering smarter solutions to benefit our customers. From optimised workflows to improved customer experiences and expanded service offerings, we have transformed the way we operate. It’s not just about having more space, it’s about using that space intelligently to deliver better results for our customers.
The message from Cobalt is clear: we’re building smarter, faster, and more cost-effectively than ever before, providing tangible benefits for our customers and partners.
