ASC Direct adds two new Boxstar lines

ASC Direct has taken a significant leap forward by strengthening its partnership with GTS Europe, installing two new state-of-the-art machines: an 1800 ‘Mini’ Boxstar and a 2508 ‘Pro’ Boxstar. This latest investment, completed in March 2026, isn't just about adding capacity; it’s about solving a complex manufacturing puzzle that many in the packaging industry face.

ASC Direct is structured in two divisions: Direct and Cartons. The Direct division focuses on e-commerce, driven by a sophisticated online ordering platform. Here, customers can use a bespoke box builder to receive instant pricing and place orders for custom-sized cardboard boxes in quantities ranging from 25 to 2,000 units. However, over 90% of orders are for 100 boxes or less.

"Producing these quantities isn't easy, especially when every single order is bespoke," explains James Palfery-Smith, General Manager, ASC Direct. “The challenge is fourfold: optimising stock board sizes to minimise waste, ensuring machines are versatile enough to handle everything from pallet boxes to mini wraps and trays, maintaining rapid turnaround times despite volatile board lead times, and, crucially, managing labour and setup costs on short-run orders.”

The introduction of the GTS Boxstar technology has fundamentally changed their business. ASC Direct was already familiar with the platform's reliability, having operated a 2508 Boxstar for nearly five years alongside three Solarco short run boxmaking machines that were also supplied by GTS Europe. The decision to add a second 2508 ‘Pro’ Boxstar and the specialised 1800 ‘Mini’ Boxstar was a strategic move to eliminate the inefficiencies of the old rotary slitter workflow.

The Boxstar's ability to slit, score, and cut in a single pass — and handle a vast array of box styles from 0401s to complex trays — means that what once required three machines and six people can now be handled far more efficiently. The ‘Mini’ Boxstar, in particular, allows for high-precision work on smaller formats, perfectly aligned with the needs of the e-commerce sector.