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OCTOBER 2026
DIGITAL PUBLISHING SOLUTIONS
DIGITAL PRINT, PACKAGING, AND PUBLISHING
INFO #7
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Unlocking Modern Efficiency with Print MIS and ERP Solutions
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departments Editor's Letter Security Focused
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Showtime........................................................................................... 5 United in PRINT .................................... 8
Spotlight Learning the Ropes
Best Practices Focus on Outsourcing ................................................................. 10 Cybersecurity Strategies for Print Providers .......................... 18 Finishing Shaping the Future....................................................................... 13 The PUR Choice ........................................................................... 16 Target Chart. Print MIS
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Advertiser Index ............................................................................ 26 Companies Mentioned
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October 2026 II dps II 3
dpsmagazine.com Volume 28, Number 6 • ISSN: 1529-2320
Security Focused Security is an increased consideration for print providers. This includes both offering security services on printed documents, and ensuring their own internal networks and devices are secure. Cybersecurity is an essential factor for production print environments. From hardware to the network, a variety of endpoints are vulnerable if not properly secured. Learn more about specific threats and concerns in Cybersecurity Strategies for Printers.
From hardware to the network, a variety of endpoints are vulnerable if not properly secured. Next we turn our focus to production workflow. Print MIS/ERP systems act as a backbone to a print business. With shorter runs, faster turnaround times, and labor shortages, print providers look to modern tools to support productivity and profits with business intelligence. Read more in our cover story, Silos to Synergy. Also find a Target Chart following this article. For print providers branching out to new applications, choosing the right finishing device is critical to success. We look at die-less digital cutters in Shaping the Future. We also highlight perfect binding in The PUR Choice.
EDITOR IN CHIEF Thomas Tetreault 978-921-7850 EDITOR Cassandra Balentine cbalentine@rockportpubs.com ASSOCIATE EDITOR Melissa Donovan mdonovan@rockportpubs.com ART DIRECTOR Sarah M. White swhite@rockportpubs.com WEB EDITOR Melissa Mueller CONTRIBUTORS Marco Boer, Kemal Carr, Olivia Cahoon, Richard Huff ADVERTISING SALES PUBLISHER Thomas Tetreault 300 Newburyport Turnpike Ste. 11 Rowley, Massachusetts 01969 Ph 978-921-7850 x110 • Fx 978-921-7870 edit@rockportpubs.com SALES Amanda Doyon Ph 978-921-7850 x170 • Fx 978-921-7870 adoyon@rockportpubs.com Subscribe online at dpsmagazine.com
For those considering adding a service offering to their business, whether it be labels, packaging, or wide format, wholesale providers may be a helpful resource. Find more information in Focus on Outsourcing. Also in this issue, hear from a new franchisee in our Spotlight column, Learning the Ropes; and read more on what to expect at PRINTING United in part two of our show preview. Best regards,
CORPORATE & PUBLISHING OFFICE 300 Newburyport Turnpike Ste. 11 Rowley, Massachusetts 01969 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault
Cassandra Balentine, editor
CONTROLLER Missy Tyler
cbalentine@rockportpubs.com Digital Publishing Solutions is published by Rockport Custom Publishing, LLC. Please send change of address forms to: 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. © Rockport Custom Publishing, LLC 2026. Reproduction by any means of the whole or part of Digital Publishing Solutions without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement. Subscription Rates: U.S. $41.65 per year, seven issues; single copies: $5.95, Canada and Mexico: $52.22 (U.S.D.), Other international subscriptions: $71.05 (U.S.D.) Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kits to Reviews Editor, DPS Magazine, 300 Newburyport Turnpike, Ste. 11, Rowley, MA 01969. We cannot be responsible for unsolicited product samples.
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showtime
United in PRINT
The Industry Convenes for PRINTING United 2026 By OPS Magazine Staff
This September, PRINTING United Expo highlights the latest innovations across commercial, industrial, apparel, packag ing, mailing, in-plant, and wide format printing. The event promises attendees will find better ways to work, new ideas to explore, and a clearer sense of future growth. Hosted by the PRINTING United Alli ance, PRINTING United takes place Sep tember 23 to 25, 2026 at the Las Vegas Convention Center in Las Vegas, NV,
On the Floor Among the hundreds of exhibitors, we highlight a few below. APS Imaging, booth N7143, demon strates advanced lay-flat binding and automated casing-in technology. See the Zeno360 IND530-2000 RF and Cas ing-In system in action and discover how APS can help take book production to the next level. INFO# 200 Agfa, booth C1149, highlights the Onset Panthera FB3216, Jeti Tauro MAX Automation, Jeti Tauro H3300 XUHS, Jeti Bronco H3300 HS, Anapur na Ciervo H3200, Asanti, and SpeedSet Orea 1060. INFO# 201
Aleyant, booth N7313, brings the fu ture of print automation. Among stand out releases is a new AI-powered feature for PrintJobManager that reads incom ing customer emails requesting quotes and automatically generates a complete estimate. INFO# 202 BW Converting, booth N7265, exhib its under the theme "Many Industries. One Purpose," it showcases technolo gies serving the print, bag converting, and mailing markets. Highlights include PCMC printing presses and anilox roll cleaning systems, Baldwin auxiliary print technologies, W+D mail inserting and converting equipment, and the W+D 449 ecommerce paper mailing bag ma chine. INFO# 203 Durst, booth C1614, features a lineup of production technology, including the North American debut of the PS 350
CORE alongside the PS 350 HS D4 and PS 350 HSR printers. INFO# 204 FUJIFILM North America Corpo ration, Business Innovation Division,
booth N6042, displays its latest portfo lio of digital print and business-develop ment solutions. Attendees are invited to explore a comprehensive lineup of pro duction print, workflow, color manage ment, educational programs, and part ner solutions. INFO# 205 HP, booth Cl 715, demonstrates the latest advances across its large format and industrial print portfolios. Visitors are invited to get a first look at the com pany's latest press and workflow innova tions. INFO# 206 1. SCREEN Americas highlights the Truepress LABEL 350UV SAi Series in booth N6143. 2. Rollem intro duces Cardistry in booth N5543. 3. RISO features the ComColor GN Printer in booth N6121.
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3 Hybrid Software, booth C1371, shows visitors how AI, GPU-native rendering, workflow automation, and advanced color management are improving productivity, quality, and efficiency across print production. Demonstrations span the Hybrid Software Group portfolio, including Labels & Packaging, Brandz, Helix, Color, Xitron, and Meteor Inkjet. Hybrid Software demonstrates a range of AI-powered solutions that simplify production workflows and automate routine tasks. INFO# 207 nfigo, booth N7149, showcases its Storefront, Workflow, and Intelligence platform pillars, including new AI capabilities. The company demonstrates how print businesses can automate order-to-production workflows and unlock new revenue through smarter, self-serve storefronts. INFO# 208 essu anufacturing, booth C2877, showcases its latest printable graphics media solutions, including TenaciousTac high-tack films, ARMORLam overlaminates, and Floor2WallPro, while highlighting its expanded capabilities through D&K Coating Technologies. INFO# 209 agnu agnetics, booth C966, features DigiMaxx and DigiMag magnetic sheeting, along with unmagnetized DigiMag Plus, DigiMag Xtra, and DigiMag Duplex digital sheets paired with Magnum magnetizer options. Live demonstrations showcase two printing 6 || dps || October 2026
technologies—the Mimaki UJ330H-160 Hybrid UV Inkjet Printer and the Xanté En/Press Digital Multi-Media Press— along with the Summa Optima V Series V1612 flatbed cutter. INFO# 210 Müller Martini, booth N6129, showcases standout technologies designed to help modern print operations produce more with less, including the Hunkeler GEN8 Direct Mail Line, Vareo PRO perfect binder, and InfiniTrim. The company also unveils the new Separo PRO, which performs live inline with the Vareo PRO perfect binder, giving visitors an exclusive first look at this latest innovation in automated book production. INFO# 211 Messe Düsseldorf, booth N6857, promotes its drupa alliance portfolio of printing trade fair organized around the globe. Visitor and exhibitor information for drupa 2028, the global stage for printing solutions—May 9 to 17, 2028 in Düsseldorf, Germany; All in Print China—October 2026 in Shanghai; Pack Print Plas Philippines—October 2026 in Manila; Print Pack Algers—April 2027 in Algiers, Algeria; and Pack Print International—September 2027 in Bangkok, Thailand, are available. INFO# 212 Nobelus, booth N5243, showcases three thermal laminators ranging from entry-level lamination to double-sided production volumes. INFO# 213 OneVision Software AG, booth N6172, demonstrates how AI-powered applications and automated workflows shape the future of print production. Presented solutions include automated prepress operations, intelligent nesting, and AI-based bleed generation, image upscaling, and background removal. INFO# 214 RISO, booth N6121, highlights the MICRXpress system. Unveiled last year, it prints full-color documents with the ability to lay down lines of MICR ink all in one pass. It also showcases its fastest inkjet printing system, the VALEZUS T2200, paired with a Plockmatic booklet maker to create the fastest booklet maker in North America. The company features
its ComColor GN cutsheet inkjet printer series, which delivers speeds of up to 180 pages per minute. INFO# 215 olle nternational, booth N5543, is excited to announce “Cardistry, the Art of Card Production,” live in Las Vegas, NV. The next-generation automated platform is engineered for high-volume playing card, trading card, and collectible card production. It integrates slitting, cutting, and collating into a single inline workflow. Cardistry is available in two models—the Single Line system, capable of processing up to 1,800 sheets per hour (sph); and the Double Line configuration, featuring dual cutting and collating sections delivering up to 3,200 sph. INFO# 216 EE ericas, booth N6143, invites attendees to discover offset-like color reproduction for commercial, direct mail, and publishing applications with the Truepress JET 560HDX, ideal paper packaging solutions using aqueous foodsafe inks with the Truepress PAC 520P, and prime and industrial labels using a seven-color gamut with the Truepress LABEL 350UV SAI Series. INFO# 217 Shark Machinery, booth N5204, invites attendees to discover the latest additions to the Shark finishing line, including the new SFP-45, SFP-330, and SFP-350 Foil Printers; the SB-660ACF Perfect Binder; and Shark’s industry-leading Paper Cutters. INFO# 218 Sharp Electronics, booth N6960, offers its most comprehensive production print portfolio yet. Attendees can preview Sharp’s complete Digital Production Press Series and are invited to explore specialty toner, workflow automation, and partner solutions, which are designed to help drive growth and profitability. INFO# 219 ignificans uto ation, in the AI Pavilion, showcases the revolutionary power of AI in combination with highly customized workflow automation. INFO# 220 u a, booth C723, debuts the F Series Vantage range, featuring the F1612 Vantage and F1625 Vantage. Designed to
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deliver higher productivity, greater ease of use, and a more connected workflow, the F Series Vantage represents Summa’s most advanced flatbed cutting platform to date. Summa also unveils innovations that further expand the F Series Vantage ecosystem. Visitors can expect the introduction of new models, alongside a range of new tools and productivity-enhancing developments. INFO# 221 Tecnau and it a, booth N7026, show live demonstrations of the Tecnau Revolution 50 AutoSetup, CutReady c7, and Tecnau Connect, alongside the Sitma eWrap packaging solution. Together, these technologies enable smarter, more automated production workflows that help print service providers turn every opportunity into profitable output, taking jobs “From Print to Profit.” INFO# 222
lti ate Tech, booth N5623 and the AI pavilion, features its latest workflow automation solutions, helping print service providers streamline production, reduce touchpoints, and maximize efficiency from prepress through finishing. Visitors are encouraged to connect with the team in the AI Pavilion to discover how intelligent automation is transforming print manufacturing and enabling smarter, faster decision-making. Stop by the booth to see live demonstrations of Ultimate Impostrip, Ultimate Bindery, Ultimate BestCut, and other innovations designed to boost productivity and profitability. INFO# 223 Vanguard igital Printing yste s, booth C1514, invites attendees to experience the power of combining American innovation with worldwide precision. Vanguard’s technology is built for today’s
production environments. See live demonstrations of the Radnor and experience an all-new printer unveiling. INFO# 224 - ite Pantone, booth C2450, features eXact 2 Basic, a new handheld spectrophotometer that makes objective color measurement more accessible for commercial printers. Combining density and L*a*b* measurement in an easy-touse, standalone device, eXact 2 Basic helps press operators move beyond visual and density-only checks for more consistent color and better production decisions. INFO# 225
nited in Print PRINTING United attendees can expect demonstrations and product launches across all print segments. For additional coverage, visit dpsmagazine.com. dps
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services the local area, it also serves several national customers and many clients up and down the East Coast. One thing Franchesca has learned about the print business is that it tends to be cyclical. There are times when it’s all hands on deck, bringing in help from family, friends, and other co-workers to meet deadlines, while other months are almost too slow. The new ownership team at Minuteman Press Matthews, NC has gotten to know its customers. For example, they do a lot of work for local churches and organizations. Many of these clients are mid-size businesses with monthly orders and are well adept at presenting what they need without too much direction or drama. These mid-size customers are the sweet spot, dream customers for Franchesca. “I love my big customers, but mid-size customers are the golden gem. They are consistent and when you show that you’ll take care of them, they come back to you.”
Of course, the print provider also operates a versatile range of finishing equipment, including the Duplo DC646 Cutter Creaser, Summa D Series cutter, hot and cold foil lamination, a folder, guillotine cutter, as well as a shrink wrap machine. It also invested in apparel products, including a heat press, hat press, and sublimation capabilities, with a single-head embroidery machine from ZSK expected to be installed in the coming weeks. “I’d love to see the apparel offerings grow. Now having a lot of the capacities in house we’ll be able to do a push for this type of work,” says Franchesca.
Production Focused
A majority of the services offered by Minuteman Press Matthews, NC are digital in nature. Its equipment lineup includes both digital and wide format printers. It operates a Xerox 4100s and a new Xerox Proficio PX500 production press, as well as two wide format printers from HP—the HP Scitex FB750 flatbed UV device, and HP Latex 330 roll-fed press. The Xerox Proficio PX500 features a fifth station for specialty inks and enhancements in order to expand capabilities beyond CMYK.
With a majority of its work digitally printed, the shop’s Xerox machines are essential to the operation. The prior owners employed multiple offset presses, but the focus is now on digital, with about 47 percent production and the rest wide format and apparel. Entering the business, the shop had two Xerox 4100s, with one coming up on the end of its lease. The Xerox Proficio PX500 was installed in April of this year, with the fifth imaging station option. The press offers color printing, built-in automation, and rated speeds of up to 100 pages per minute. The fifth color station was important to Franchesca’s vision for the future. “We’d love to expand on that, showcasing what the fluorescents and gloss can do.” At press time, the company was settling in with the new press. The first order that called for clear gloss came about after a networking event where someone asked if she could duplicate a
COMPANIES MENTIONED
See page 26 for more information.
Knowing and Growing
COMPANY
WEBSITE
INFO#
Duplo USA, Inc.
duplousa.com
100
HP, Inc.
hp.com
101
Summa
summa.com
102
Xerox Corp.
xerox.com
103
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real estate brochure. “I could tell it had a UV coating and I knew we could match it with the Xerox Proficio PX500 clear gloss. We did it with a clear gloss and it came out perfectly. The difference between the two was negligible. Now, this customer will order these brochures in small increments because we have the ability to do that,” notes Franchesca She is also excited to get into more fluorescent work. She notes the Minuteman Press logo has a specific orange, P165—a spot color it couldn’t accurately hit before the Xerox Proficio PX500. The print provider is slowly transitioning all marketing materials to include the vibrant logo as it should be, which is sure to generate attention to the pop in color it now offers. Getting its Xerox machines to run optimally did take some work. Franchesca admits there were challenges early on, but credits Xerox’s sales and service teams for staying engaged and working through those issues. One Xerox technician in particular made a significant difference by taking the time to listen, understand the challenges, and work through them alongside her team. She admits that while the machines weren’t at 100 percent when she first got on the scene, the company’s commitment to finding a solution helped get the equipment performing to her standards. “When we had challenges at the beginning, the sales technician really listened to what we had to say. I expect perfection out of our machines and we didn’t stop until we got there,” says Franchesca.
High Expectations Coming into a new industry takes courage, commitment, and creativity. Franchesca has it all. The Minuteman Press Matthews, NC franchise continues to invest in solutions that align with its goals and support expansion. Technologies like the Xerox Proficio PX500 promise opportunities for high-value digital offerings that pop. dps October 2026 || dps || 9
Focus on Outsourcing Free Up Time and Resources with Trade-Only Printing By Melissa Donovan
Hundreds of applications continuously pop up and if a print buyer is savvy, they will make note and most often reach out to a trusted print provider to in uire if a similar ob is possible. But what if that print provider doesn’t have the expertise or hardware in house to achieve the quality and reliability that customer has come to expect? That’s when trade-only wholesale printers enter the e uation. These businesses offer a true partnership with commercial printers looking to capitali e on print trends without a ma or investment.
Best to Outsource
this more specialized work onto a trade printer. “Every printer has a sweet spot, the place where their equipment, employees’ skills, and ideal applications come together to earn maximum profit. Every job they take outside of that sweet spot is potentially costing them money. By outsourcing the work that falls outside that
sweet spot, printers free their equipment Many print service providers (PSPs) are to run the jobs that pay best,” suggests surprised to discover that certain speBob Saunders, VP of sales, Wise. cialty products are often more cost effecLabels, checks, unit sets, wraparound tive to outsource than to manufacture in forms, and continuous forms are among house, states Jennifer Hoyt, director of the products Saunders sees many commarketing and ecommerce, Stouse. mercial printers offload to trade printers. “Across the U.S. print market, many “Industrial and durable labels are a providers still keep in-house common example. A commerproduction on jobs that are betcial printer might accept a job for ter suited for specialized trade chemical drum labels or equipEvery printer has a sweet spot, the place environments due to equipment ment nameplates because a good where their equipment, employees’ skills, intensity, finishing complexity, or customer asked. But those jobs and ideal applications come together to volume inefficiency,” admits Luis require specialized substrates, Perez, GM, TradeOnlyFolders. earn maximum profit. 1. & 2. Stouse produces custom printed Depending on the print proproducts, including decals, magnets, roll — Bob Saunders, VP of sales, Wise viders’ main services/offerings, labels, signs, plastic products, and other specialty print solutions.
it might be less expensive to pass
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adhesives, and compliance knowledge that the printer may not have. Producing them in house means slow turnarounds, spending time on trial-and-error materials, and tying up a press that could be running the high-margin work the shop does best. Sending that job to a trade manufacturer who already has the materials, expertise, and certifications is faster, cleaner, and often more profitable,” recommends Saunders. Decals, static clings, contour cut vinyl lettering and graphics, roll labels, magnets, parking permits, plastic cards, corrugated signs, and other durable graphics, are other examples. “These specialty items frequently require specialized materials, finishing equipment, or finishing-intensive production processes that aren’t practical to maintain for occasional jobs,” notes Hoyt. Other common applications, according to Perez, include categories like presentation folders in standard and custom configurations, foil and spot UV business cards and postcards, pocket folders in mid-to-large quantities, booklets above approximately 2,000 units, and perfect bound books. “In many cases, these products require multiple production stages and specialized finishing equipment that can create bottlenecks for smaller or general commercial print shops. Moving these jobs to a dedicated trade partner allows print providers to better balance capacity, reduce production pressure, and improve overall turnaround efficiency,” explains Perez. Another advantage, “outsourcing these applications enables printers to expand product offerings without investing in additional equipment, inventory, or labor. It frees up valuable press time, allowing them to focus on the work they do best while still saying ‘yes’ to more customer requests,” shares Hoyt.
to ease any concerns about quality, consistency, and turnaround time. TradeOnlyFolders maintains a formal quality assurance (QA) process led by an internal QA manager who reviews production standards across prepress, print, and finishing. Each job follows defined checkpoints to ensure accuracy and repeatability. Wise’s Anderson, SC labels plant has held ISO 9001:2015 certification for 24 consecutive years. “That means consistent quality across every order, documented controls and traceability, and faster issue resolution, exactly the assurance customers with demanding jobs expect,” says Saunders. Additionally, blind shipping is a bonus that “enables partners to ship directly to their customers under their own branding, with no reference to our facility,” adds Perez. The aforementioned practices allow trade-only printers to operate as an extension of their customers’ businesses. “We understand that we’re an extension of our customers’ businesses, so our success depends on delivering the consistent
quality, reliable turnaround, and responsive support they need to confidently serve their own customers,” says Hoyt.
Efficient Production Producing jobs as cost effectively as possible is a win for all of the parties involved in the process. “From a trade perspective, the main advantage is scalability—handling higher volumes without compromising consistency or extending production timelines,” explains Perez. The TradeOnlyFolders facility is built around automation, powered by Enfocus Switch, which connects file intake, prepress processing, imposition, and production routing into a unified automated workflow. “This system allows us to automate repetitive prepress tasks, efficiently group compatible jobs through gang runs, and reduce manual touchpoints throughout production. The result is improved production speed, reduced labor dependency, and greater consistency across high-volume orders. In many cases, this infrastructure also enables faster
Causes for Concern—Debunked Trade printers operate invisibly. They must work and match the PSP’s methods
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production cycles, including same day and accelerated turnaround products depending on job type,” continues Perez. Hoyt points out that since specialty products are companies like Stouse’s core business, trade-only printers invest in equipment, workflows, and finishing capabilities that many commercial print providers don’t need to own themselves. “Those efficiencies help us manufacture these products economically, while eliminating the need for customers to invest in equipment, maintenance, inventory, and labor associated with expanding production in house,” continues Hoyt.
Wise requires a resale certificate and references before setting up an account.
Look at What’s Out There
Just because a print shop claims to be trade only, doesn’t always mean it is. It’s important to verify prior to starting an outsourcing relationship. Stouse has businesses complete a verification process during account setup to confirm they are purchasing products for resale. “That distinction is important because our customers trust us with their business. We don’t compete for end user customers, allowing print providers to confidently position us as an extension of their own production capabilities while maintaining ownership of the customer relationship,” shares Hoyt. TradeOnlyFolders reviews and verifies during onboarding to confirm that customers are legitimate print resellers, agencies, or industry professionals. Reseller documentation is validated where applicable.
Several providers focus on printing to the trade. 4over operates as a business-to-business wholesale trade printer, offering services and discounted wholesale pricing only to qualified businesses that resell its print products to other businesses and individuals. It specializes in business cards, marketing products, signs and banners, boxes and packaging, roll labels and stickers, promo products, and direct mail services. The FireSprint guarantee involves fair wholesale pricing, accurate orders, fast production, and friendly service. SinaLite, in business since 1999, is a wholesale trade printing company and custom packaging manufacturer. Offering over 1,000 product options its core values are passion, growth, innovation, and customer success. Signs365 is a grand format, trade-only wholesale printer. It offers a variety of full-color, high-quality printed products all produced in 24 hours. $10 Overnight Anywhere shipping is available on all products. Stouse helps customers sell more while focusing on the work they do best by combining broad manufacturing capabilities with responsive customer service, blind shipping, online ordering tools, and free sales resources. It produces a range of custom printed products,
COMPANIES MENTIONED
See page 26 for more information.
Verification of Trade
COMPANY
WEBSITE
INFO#
4over
4over.com
125
FireSprint
firesprint.com
126
Signs365
signs365.com
127
SinaLite
sinalite.com
128
Stouse
stouse.com
129
TradeOnlyFolders
tradeonlyfolders.com
130
Wise
wbf.com
131
WS Display
wsdisplay.com
132
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including decals, magnets, roll labels, signs, plastic products, and other specialty print solutions. TradeOnlyFolders differentiates itself through a combination of specialization, operational depth, and direct customer support. The company brings more than two decades of focused experience in presentation folders, which remains one of its core production strengths. Over time, this specialization has evolved into a highly refined production system with redundant equipment pathways designed to ensure stability during peak demand periods. Wise is a trade-only manufacturer of business forms and industrial and prime labels, serving print distributors and resellers exclusively since 1969. It is known for solving label and forms problems other manufacturers can’t, engineering custom solutions like dual-substrate consolidated carriers, placard labels for returnable totes, and tags that survive 1,700 degrees Fahrenheit heat treatment. It offers both forms and labels under one roof, which is unusual in the trade. It backs all of it with a trade-only commitment, five strategically located plants for fast nationwide delivery, the WiseLink ordering portal, and its ROPE repeat-order prediction tool. WS Display specializes in wholesale portable trade show displays, banner stands, and large format digital printing. WSDisplay.com solely markets its services and products through authorized distributor partners in a collection of diverse distribution channels.
Trade-Only Printing Wins Trade-only printing is an important part of the commercial print world. Without these businesses it would be challenging to get certain items printed and break into new markets, because not everyone is specialized in popular applications and has the capital to invest in new equipment. This means it makes sense to outsource certain work. dps
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Producing Prototypes Digital cutting is particularly well suited to prototyping because it eliminates the need to manufacture expensive dies for every new design. Specific benefits include eliminated tooling costs, rapid design iterations, faster approval cycles, accurate representation of final production quality, and the ability to create highly customized, one-off samples. Also, the use of digital files for cutting does not restrict the number of changes, “as it is a simple edit of a digital file to create new cutting templates and this can then be used to communicate directly with the cutter to use the specific tools required to produce the prototype or packaging,” says Terri Winstanley, marketing manager, packaging and labelling division, Plockmatic Group. “Designs can be modified instantly, allowing multiple iterations to be produced within minutes, reducing development time and material waste. The technology delivers production-quality prototypes with accurate cutting and creasing, enabling designers to validate fit, form, and function before committing to full production.” “For prototyping, digital cutting is ideally suited for producing packaging samples, mockups, and design iterations quickly and accurately, making it the preferred solution for prototype development,” offers Thornton. “Packaging designers can quickly create, test, and modify concepts within minutes or hours rather than days,” shares Matteo Muto, product manager, Summa. “This flexibility enables packaging developers to validate structural designs, graphics placement, material selection,
and consumer experience before committing to production.” “When brands request work, they often need it to be done and out the door as soon as possible, something that only digital cutting tables can enable,” comments Newell. “This is further achieved due to technologies such as camera systems and vision recognition software, which ensure that the first piece that is cut is a high-quality saleable sample, whereas legacy technology sometimes takes five to ten attempts to get one good sample. This minimizes approval time and facilitates quicker response to customer requests, contributing to quicker turnaround times.” Speed and flexibility are essential. “A print provider can move from a digital design file to a finished sample without waiting for a physical die to be manufactured. This allows packaging designers, brand owners, and printers to test shapes, folds, materials, and structural concepts quickly,” offers DiPirro. Thornton agrees, pointing out that systems using digital, computer-controlled knife cutting and routing technology are highly adaptable to any kind of production scenario. More widely, Newell says digital cutting reduces production costs by enabling materials to be ordered when needed. Muto sees few limitations in a prototyping environment. The primary consideration may be material compatibility or the need to replicate very specific production effects intended for high-volume converting equipment. It is important to always ensure you’re utilizing the correct technology for the
COMPANIES MENTIONED
See page 26 for more information.
COMPANY
WEBSITE
Graphic Whizard USA
graphicwhizard.com
INFO# 145
Kongsberg Precision Cutting Systems
kongsberg.com
146
Plockmatic Group
intecprinters.com
147
Summa
summa.com
148
Zund America, Inc.
zund.com
149
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requirement. “For example, for organizations producing very high volumes of prototypes or requiring greater throughput, a more productive platform such as the Kongsberg C or Ultimate may be more appropriate,” says Newell. DiPirro adds that each material and structure may require some testing to determine the best tool, blade, pressure, and speed settings.
Short-Run Territory For short-run packaging, digital cutting provides the flexibility to switch quickly between jobs without lengthy setup processes. Thornton says it supports cost-effective production, rapid turnaround times, and consistent quality, even as order volumes, designs, or material requirements change. “As brands increasingly demand versioning, personalization, and shorter product lifecycles, digital cutting has become a compelling solution for short-run packaging production,” comments Muto. For short-run packaging, DiPirro explains that digital cutting helps eliminate the cost and lead time of traditional dies, which can be a major barrier for smaller quantities. “Runs around 2,500 pieces often require a balance between automation and flexibility. Automatic sheet feeding, barcode recognition, mark registration, and multi-tool capabilities allow print providers to produce short-run packaging efficiently while still handling frequent job changes, custom shapes, and versioned designs.” Because digital cutting technology also facilitates better versioning, Newell says it enables cost-effective production of seasonal and promotional packaging. For print providers moving into packaging, Baker says the single biggest hurdle is rarely the printing itself. It is the mental and operational leap from a world of predictable, repeatable bulk to one of constant changeover. The good news is that the technology to dissolve that barrier has matured rapidly. “Over
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the past three to five years, the most significant workflow advancement has been the move to fully digital, tangential cutting and creasing—where a tool head follows a digital file rather than a physical die. The advantages for prototyping are clear—no tooling cost, no lead time, and the freedom to iterate a design on screen and produce a finished, folded sample within minutes. For short-run packaging, the same technology turns what would once have been loss-making work into profitable production, because every job carries the same low setup overhead regardless of quantity.” Thornton admits that while run lengths increase and jobs become highly standardized, conventional die-cutting may offer greater economies of scale. “The crossover point depends on factors such as run length, design complexity,
material, turnaround requirements, and the level of automation in place.” Newell often sees a mix, where producers use digital cutting solutions as complementary technology alongside conventional die cutting. So, the digital cutting technology is used for shorter runs and immediate production, while conventional die cutting is being prepared for longer runs,” comments Newell. Digital die-less cutting technology is ideally suited to short-run packaging, but for very high production volumes, Winstanley admits that conventional die cutting is generally more economical due to its higher throughput. “Production speed is lower than dedicated high-volume die-cutting equipment, and the range of materials, sheet sizes, and thicknesses is dependent on the machine model and tooling configuration. However, as the
packaging industry continues to embrace more sustainable manufacturing practices, digital die-less cutting provides an environmentally responsible alternative by reducing tooling waste, minimizing material waste, enabling on-demand production, and lowering inventory requirements.”
Cut it Out In today’s packaging market, speed, agility, and personalization are critical competitive advantages when it comes to finishing. “Digital cutting technology provides manufacturers with the flexibility needed to respond rapidly to changing customer demands while maintaining exceptional quality and efficiency,” concludes Muto. Find more information on digital cutting solutions and strategies for packaging online at dpsmagazine.com. dps
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handling, and 24 hours to a near full cure time. EVA adhesive can be re-melted numerous times in binder tanks and gives a nice firm bind when cured,” explains Darryl A. Drever, senior proSUPPORT technician, Skandacor. PUR on the other hand is a polyurethane reactive adhesive. “It binds by cross linking at the molecular level to the fibers in the paper to create a very strong, yet3somewhat flexible bind that caters to a more layflat characteristic especially on larger or thicker books. For PUR, instead of notching, the spine of the book is prepared by shredding or fraying the paper of the spine to expose paper fibers that make contact with the PUR adhesive and can become an integrated part of the finished bind,” shares Drever. In summary, PUR and EVA are both hot melt adhesives, but differ in how they
cure. “PUR is a moisture curing adhesive. It draws humidity from the air and paper fibers, which triggers a chemical reaction that transforms the glue into an elastomeric film that cannot be re-melted. In contrast, traditional EVA cures as its temperature cools. It can be heated into liquid form, and then it re-solidifies when cooled,” explains Miles. According to Ed Hudson, GM, Plockmatic Group UK, PUR is usually preferred because of its ability to adhere reliably to difficult stocks such as heavily coated, UV varnished, or tone rich surfaces—places where EVA struggles. PUR also accomplishes a superior bind while using a thin layer of adhesive, notes Drever, one that finishes with a clean semi-translucent appearance. PUR limitations include higher adhesive cost per kilo, the need for controlled
humidity/temperature, and longer cure time compared with EVA.
Choose PUR PUR adhesive is used for perfect binding digitally printed books due to its bond strength, flexibility, durability, and ability to adhere to challenging coated and digitally printed substrates. Despite its benefits, PUR does present challenges, namely longer curing times. As a result, EVA remains a practical option for applications requiring faster turnaround. Advances in closed-loop nozzle systems, automation, workflow integration, and smart factory technologies help reduce traditional limitations of perfect binding while improving efficiency, consistency, and operator safety. dps See page 26 for more information.
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October 2026 || dps || 17
passwords are not maintained on the devices, the risk of malicious attacks becomes very high,” offers Grafanakis. Production drives may hold sensitive materials. Mike Betsko, senior director, business planning and strategy, enterprise and solution products, Canon U.S.A., Inc., says if compromised, this could result in compliance issues. Workflow connectivity is a cybersecurity threat. Modern print operations accept work through hot folders, automated job submission, W2P portals, MIS/ERP integrations, and cloud services. Secure DFEs should support timely software updates, hardened operating systems, controlled network ports, secure integrations, and centralized identity management, according to Czakis. Network pivoting is another concern. Betsko says attackers use devices with
weak security as a “beachhead.” Once they compromise the DFE, they can pivot laterally to attack other systems. A blog posted by Kodak, Why Security in the Print Industry Matters More than Ever, notes that while the digital transformation has unlocked new efficiencies, it has also introduced new vulnerabilities, especially in the software that powers modern print operations. As a result, printers can no longer afford to be complacent. “They must be agile and responsive to meet evolving challenges, especially when it comes to proactive security strategies.” Physical and insider access is another risk. “Production floors are busy, shared spaces where job files sit on servers and printed output sits on pallets. Unrestricted operator accounts, shared administrator credentials, unattended
output, and drives that leave the building for service are all realistic paths to a data loss that circumvents the digital network,” says Czakis. Betsko agrees, suggesting that malicious or careless employees can exploit weak access controls to print unauthorized copies of sensitive documents or siphon off data using USB drives.
Cybersecurity Considerations Digital production printers and presses are not isolated islands; they are fully networked nodes, making them potential targets like any other technology today, notes Betsko As Kodak’s blog says, “across the print industry, print security is no longer just an IT issue, it’s a business imperative.” dps See page 26 for more information.
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Dataline systems are designed to support actual production registration through barcode scanning, shop-floor data collection, operator terminals, mobile devices, JDF/JMF integration, and machine feedback where available. After production, the system compares what was estimated with what actually happened. “This creates a continuous learning loop. If setup takes longer than expected, a machine performs below its standard speed, waste is higher than estimated, or if a customer consistently generates low-margin work, management can act on facts rather than assumptions,” adds Deroo. On the shop floor, operators can clock in and out of jobs or machines, record production time, register material usage, report quantities produced, use
touch-based interfaces, and scan barcodes to load job information. Vogt Mikkelsen explains that this data is fed into the job costing system and compared with the original estimate. Companies can then see differences in labor, materials, and overall cost, as well as margins and profitability. Pace’s integration with Auto-Count 4D lets operators log actual time and materials via barcode scanning and shopfloor terminals. “That real production data flows back into the job to reconcile against the original estimate, giving an accurate actual-versus-estimated comparison instead of a manual reconciliation process,” says Ward. By reconciling Auto-Count 4D actuals against the original Pace estimate, shops get a true margin comparison at the job level, which can be rolled up by client
or time period through reporting. Ward explains that this feedback loop shows where estimating assumptions are off and lets shops recalibrate pricing for similar future jobs instead of guessing.
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Today’s print providers and converters must find simplicity in complex workflows in order to remain profitable on more complex jobs that are shorter in length and expected faster. The challenges are compounded with a shrinking pool of skilled operators. Modern MIS/ERP systems utilize analytics to measure returns, actual costs, and inventories. For more information on print MIS, visit dpsmagazine.com where you'll find additional content as well as a webinar on the topic. dps
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