The groups Digital site in Nottingham will handle laser personalisation on Xerox presses, including 50 flash messages based on customers shopping habits.
Polestar has also developed a bespoke software system for Tesco that uses data provided by the supermarket to target consumers.
The base material has been printed 10-colour web by Polestars Connect plant in Leeds before personalisation at Nottingham.
Each pack comprises personalised statements, magazines, vouchers and inserts. The group did a similar job for Tesco in August.
Polestar has worked with Tesco since the launch of the Clubcard scheme in 1995. Mailings have grown from an initial 30,000 print run to todays 10m-plus. Polestar has now mailed a total of over 250m items for Tesco.
Polestar has also won the contract to produce the customer magazine for DIY chain Homebase.
The quarterly Homebase Ideas Magazine, which is published by London-based contract publisher Publicis Blueprint, will launch this month.
London-based Zebra will handle the repro for the magazine.
Publicis Blueprint managing director Jason Frost said the publisher was using Zebra for the first time.
We used them to do the repro on the pitch. They did such a fantastic job that we decided to let them have the job, he added. Its been eight weeks from pitch to print.
The A4 perfect-bound magazine will have an initial print run of 500,000 and the first issue is 100pp.
Story by Gordon Carson
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