Canon Workflow at DS Graphics | Universal Wilde
Automated PRISMA workflow from Canon puts DS Graphics | Universal Wilde firmly in command as it meets strict SLAs and complex variable data requirements in a high-volume direct mail environment. Learn how PRISMA’s range of options gives them a solid process for controlling projects, managing costs, and preventing downtime.
Transforming High-Volume Direct Mail: Canon Workflow Solutions Help Drive Operational Agility
In the highly competitive commercial printing industry, capturing new market opportunities requires an aggressive approach to technological innovation. For modern printing operations managing massive communication campaigns, high-volume direct mail—particularly self-mailers and postcards—represents a massive avenue for sustained business growth.
Historically, large legacy companies dominated this specific space, but they often forced their customers to compromise by relying strictly on static printing methods. To truly stand out in today's marketplace, print providers need the ability to offer highly customized variable data printing without sacrificing image quality or driving up production costs. Recognizing this industry-wide gap, print organizations require an advanced digital printing infrastructure to completely revolutionize their high-volume direct mail offerings and capture this vital market share.
Overcoming the Limitations of Legacy Systems
Delivering high-quality, variable data at scale presented several distinct operational and financial hurdles for DS Graphics Universal Wilde. In the past, achieving the necessary quality for customized, variable data campaigns meant relying on cutsheet devices, which could be five to ten times more expensive to operate than other printing methods. Additionally, the company faced immense pressure from strict Service Level Agreements required by highly demanding insurance and financial clients. These stringent regulatory and corporate contracts leave absolutely no room for error, requiring guaranteed delivery dates with zero wiggle room.
Under their previous infrastructure, if a legacy machine went down, the entire workflow was strictly technology-specific, meaning the production team could not simply transfer the prepared job to another device. This technological limitation often resulted in data groups being called into the facility at two in the morning just to start the entire job over from scratch to meet morning deadlines. Furthermore, the sales and estimating teams struggled to accurately predict ink costs before receiving the actual customer files, creating a significant risk of revenue loss when final yields differed from initial estimates.
A Unified Ecosystem of Hardware and Software
To help overcome these significant operational bottlenecks, DS Graphics Universal Wilde integrated comprehensive printing and workflow solutions from Canon. The technological overhaul was anchored by the Canon ProStream, a state-of-the-art continuous feed inkjet press known for its exceptional speed, media flexibility, and high-quality output. This advanced press possesses the robust capabilities necessary to handle a diverse range of heavy paper stocks and wider web formats with ease.
To support this powerful hardware, the production floor implemented Canon PRISMA workflow software, alongside complimentary software programs, to prepare data and documents for seamless submission. This software serves as the central operational hub, seamlessly connecting data and files across the company's multiple facilities. The workflow architecture was strategically designed to allow files to be ripped, trapped, and fully prepared within the PRISMA environment before being routed to the appropriate press or geographical location.
To help maximize the sheer output speed of the new Canon press, the facility also strategically optimized its finishing processes. By utilizing inline finishing for highly repetitive jobs and offline finishing for complex applications with varying paper types, the operators ensured the Canon printer could simply run continuously without unnecessary setup interruptions.
Financial Precision and Outstanding Reliability
The integration of Canon’s comprehensive technology suite helped to deliver transformative benefits, improving both financial profitability and daily operational reliability. On the financial side, the PRISMA workflow software features a highly advanced estimator tool that accurately calculates ink usage as soon as a file is received. This crucial step ensures that the initial job estimates align perfectly with actual production costs, preventing yield discrepancies that was previously costly for the company.
Operationally, the software's ability to act as a central hub helped to eliminate the nightmare of middle-of-the-night rework. If a specific printer experiences an issue, production managers can instantly route the fully prepared files to a backup facility, allowing jobs to be printed and mailed on time without restarting the data processing phase. The Canon ProStream itself has proven to be incredibly reliable, running almost constantly across three full shifts with virtually no downtime. This remarkable hardware uptime is heavily supported by Canon's dedicated service technicians, who provide outstanding, proactive preventative maintenance to ensure the machines are always operating at peak performance.
Securing the Future of Commercial Print
By leveraging an integrated ecosystem of advanced presses and intelligent workflow software, the printing organization successfully captured a highly lucrative segment of the direct mail market. The seamless synergy between robust hardware and intuitive software management ensures that demanding client expectations are consistently met with zero compromises and absolute efficiency.
Interested in learning how Canon production printing technology can help your business grow? Contact us today.