How Delta Group and Agfa’s Orca are Redefining the Future of Print

In a rapidly evolving print industry, agility, innovation, and efficiency are the cornerstones of success. Delta Group, a powerhouse in the UK’s printing sector, is not only navigating these changes but actively shaping the future. In an exclusive conversation on the FuturePrint Podcast, Martin Shipp, COO of Delta, and Matt Brooks of Agfa detailed how their collaboration is driving a transformative shift through the adoption of Agfa’s cutting-edge Orca printing technology. This article is inspired by a recent podcast interview with Martin and Matt.

Delta Group’s Strategic Evolution

Delta Group, a 35-year-old privately owned company, has steadily grown into a major player in the print industry. In December 2024, the company completed a monumental move, relocating 450 staff from its Waltham Cross site to a state-of-the-art facility in Bishop’s Stortford. This move consolidated Delta’s operations and set the stage for further technological advancements.

“Moving a business is one of the most stressful things you can do—right up there with having children or getting divorced,” Shipp quipped. But despite the challenges, Delta retained 99% of its workforce, reinforcing its strong corporate culture and commitment to its team.

Delta operates across several divisions, including Delta Display, Delta Creative, Odessa Print, and Superior, serving diverse sectors such as retail, film, and entertainment. With an annual turnover projected to reach £130 million, Delta is well-positioned as a leader in the UK print industry.

“We’re number one,” Shipp confidently asserted. “We serve markets that require speed-to-market, high-quality, large-format printing. That’s where we thrive.”

A Partnership with Purpose

Delta’s strategic partnership with Agfa marks a significant step forward. At the heart of this collaboration is Agfa’s Orca, a high-speed, water-based, single-pass inkjet press that represents a breakthrough in digital printing. The first Orca in the UK has been installed at Delta’s new facility, making Delta an early adopter of this game-changing technology.

“Delta is the perfect partner for Agfa,” said Brooks. “They have vast connections, a broad market presence, and extensive experience transitioning from analog to digital. That makes them an ideal testing ground for the Orca.”

For Agfa, Delta’s expertise in handling a variety of materials and its commitment to pushing the boundaries of digital printing provide invaluable insights. Delta, in turn, gains access to cutting-edge print technology that enhances its production capabilities and strengthens its market leadership.

The Power of the Orca

So, what makes the Orca so special? The answer lies in its unique combination of speed, flexibility, and sustainability. As a water-based, high-speed, single-pass inkjet press, the Orca enables Delta to print on a wide range of substrates, from lightweight paper to corrugated board.

“The Orca is a step-change,” Brooks explained. “It offers a differential that sets it apart—water-based technology at high speed, with exceptional quality and cost efficiency.”

The flexibility of the Orca allows Delta to experiment with different substrates, potentially even venturing into semi-synthetics in the future. The machine’s ability to handle variable data also gives Delta a significant edge in the era of personalized and on-demand printing.

“With digital, it’s not about printing 10,000 identical sheets anymore,” Shipp noted. “It’s about handling multiple smaller orders efficiently, reducing manual handling, and minimizing errors.”

Sustainability and Efficiency: The New Imperatives

One of the key drivers behind Delta’s investment in the Orca is its sustainability potential. With increasing client demands for environmentally responsible printing, the shift to water-based inks is a critical step.

“Many of our clients are on a journey toward sustainability, and they look to us for guidance,” Shipp said. “Reducing waste, eliminating touchpoints, and leveraging digital print intelligently are all part of our strategy.”

Agfa’s expertise in chemistry, ink formulation, and material compatibility plays a crucial role in ensuring that the Orca not only meets but exceeds environmental standards.

“The industry is moving away from solvent-based and UV technologies toward more sustainable solutions,” Brooks added. “The Orca is a big part of that transition.”

From Beta to Full-Scale Production

Being an early adopter comes with challenges, but Delta is no stranger to pioneering new technologies.

“We’ve been through this before,” Shipp noted. “We’ve taken risks on new tech, and we’ve learned from those experiences. The Orca is proving its worth already.”

As the press moves from beta testing to full-scale production, Delta is ramping up its operations. Currently running on a five-day schedule, Shipp expects to shift to a two-shift model within weeks.

“This machine is built for volume,” he said. “We’re looking at a major step change in production capacity.”

The proximity of Delta’s facility to Agfa’s R&D hub in Cambridge further enhances the collaboration, allowing for quick refinements and hands-on support.

A Glimpse into the Future

For both Delta and Agfa, the Orca is more than just a new piece of machinery—it represents the next phase of digital print evolution.

“This is only the second Orca ever built,” Brooks said. “It’s the beginning of a new era. We see it eventually replacing large-volume analog assets.”

Much like the transition from screen printing to UV flatbeds in the early 2000s, the industry is now witnessing a shift towards high-speed, water-based digital printing.

“Orca is leading that transformation,” Brooks asserted. “It’s about making digital not just complementary to analog, but a full-fledged alternative.”

Final Thoughts: A Transformational Partnership

The collaboration between Delta and Agfa is a testament to the power of innovation and partnership. By embracing new technology, Delta is reinforcing its position as the UK’s premier print provider while helping Agfa refine a revolutionary product for the global market.

“This isn’t just about today—it’s about the future of print,” Shipp concluded. “We’re not just adapting to change; we’re driving it.”

As the print industry continues to evolve, Delta and Agfa’s partnership serves as a blueprint for success—one that balances technology, sustainability, and strategic vision. With the Orca now in full operation, the industry will be watching closely to see how this game-changing technology reshapes the print landscape.