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Kernow coatings started off life back in 1974 as Sensitisers (Western) Ltd.  In the early days, the whole business was housed in a single building.  However, success in its original field of diazo film coating let to growth and the company became Sensitisers International Ltd. in 1989, as its product and customer scope broadened around the world.  The name is still known by specialists in many countries.

From the very beginning, its coating plant was developed in-house, and a team of engineers is constantly involved in building and modifying equipment to enable the company efficiently to meet ever-changing market needs.  Flexibility through internal assets has been a very important factor in the Group's diversification, growing out from its original diazo base into product areas that have enabled continued stability and progress.

Kernow Coatings (now increasingly dubbed KC) was originally set up to convert reels coated by Sensitisers International into different finished forms.  As time went by, customer demand meant that an ever-increasing amount of the Group's sales went out as product transformed from mill reels in some way.  In April 2002 Sensitisers International was merged with Kernow Coatings (Kernow is the old Cornish name for Cornwall) as by then KC was the name known by more customers than the original Sensitisers.  This has created a combined business capable of supplying everything from thermostabilised polyester in reels to OEM-packaged products, and all through the single customer service point.

Sensitisers still exists, but only as a holding company for KC and certain other interests, including Transport Distribution Services (Western) (TDS) which complements the use of external carriers with regular UK deliveries.  This can be very helpful where confidential or security products are concerned, increasing assurance of security through a single supplier.

The coating division of KC now has 5 coating machines and a dedicated thermostabilising unit, developed and built by our own staff.  Every machine has a different combination of features.  Although the company's environmental strategy has led to the majority of its coating formulations being water-based, these machines enable both aqueous and solvent coating, up to three coatings in one pass, to a maximum of 60", on film and specialist papers including lamination of pressure-sensitive adhesives.  Adhesives of different strength and cure properties are used for different applications; from 'lifetime' labelling, to wet-mounting on exhibition boards, and suction cling for promotional and industrial applications.

A particular characteristic in the ability to produce short runs of speciality products, and the willingness to undertake bespoke manufacture for other film producers and distributors.  In fact, this flexibility has led to a product range too broad to list fully.  Suffice it to say, product lines now encompass:

• traditional reprographic films and papers
• lighting filters for the movie and television industry
• the widest variety of UK-manufactured materials to the ever-growing Inkjet and Laser digital imaging materials market
• the most comprehensive range of own manufacture substrates for professional, digital large-format advertisements and graphic displays of all technologies
• specialist label reelstock and sheets
• coloured films for laser and thermal transfer applications
• base polyesters to top stability specifications
• manual laminating and protection products
• litho, flexo, and silkscreen synthetics, both plain and self-adhesive
• specialist printing plate and industrial films

The Coating division benefits from rigorous internal controls, with dedicated Quality Assurance and Environmental functions. Compliance with the Environmental Protection Act has been a fundamental part of our development and manufacturing strategy for years. We have been continually replacing solvent coatings with water-based versions that have resulted in remarkably robust performance, without environmental compromise.

The breadth of product is enabled by the work of a dedicated Research, Development and Technical Support department, based in Penryn, which engages in both long-term research and rapid modification of formulations to create commercial solutions for particular customer requirements. Hundreds of formulations have been created over the years, and this formidable bank of knowledge on the needs of diverse industries gives us a large store from which to draw answers to new challenges.

The converting division of KC processes internally-coated product (as well as some factored items), to rolls and cut sheets. Within digital imaging products, KC is experienced at adapting packaging and brand support to customer specification, with a dedicated and heavily used, sample function. Being essentially a bespoke manufacturer, the company is equally pleased to supply in pre-packaged or as "bulk-packed" for customers to put into their own final packaging. Success in Kernow's strategy is leading to increasing exports of finished items. Able to convert large orders on requirement or supply small quantities from stock. KC works closely in the UK with the Group transport company, TDS.

Kernow coatings has come a long way since its roots in diazo film.  The challenge to diversify has been embraced, and the enthusiasm of the people within the business has been a major factor in its success in reaching that goal. 

Apart from Sales and Marketing offices scattered around England, Kernow operates from a single industrial estate in Penryn, Cornwall, as shown to the left.  The foreshortened buildings in the top right-hand corner are not as small as they look.  Housing the original Sensitisers (Western), they are now, apart from a  training area upstairs, dedicated to the Research and Development department.  Besides three pilot coaters, it has its own mixing facility and a 60" 'semi-tech' machine to help establish product viability before breaking into main production schedules.

The warehouse buildings at top centre contain a large amount of raw material stock prior to coating.

The staggered building about a third of the way down house the main coating machines and an area set aside for lighting filter conversion.

All the buildings at the bottom centre and left are dedicated to various converting operations, slitting, sheeting, rewinding, perforating and the like, along with finished goods stock and the main administrative functions.

The business is still funded on the original principles, and we pride ourselves in providing a full service, using mostly in-house resources, ranging from R&D through to coating, converting and final delivery of the finished product to our UK and global customers.  Since the 1970's the company has developed and diversified to embrace the demands or today's most exacting of marketplaces.  Always in the forefront of product development, we are continually introducing new and innovative 'solutions' to a whole host of coating and imaging challenges.  With a continuing investment programme now reaping benefits, including the use of nanoparticle technology, we are better placed than at any time in the past to capitalise on the opportunities presented to one of the most flexible and forward-looking coating businesses in the UK.

Registered in England No. 1092182 Registered Office : Kernick Road, Penryn, Cornwall TR10 9DQ