How Hybrid Production Changes the Printing Game

 

Hybrid printing offers significant advantages over traditional analog processes. The blended approach integrates multiple print technologies within a single system, leveraging the strengths of various printing methods. Offset lithography’s high-quality output, for instance, and digital printing’s personalization capabilities. The synergy of these technologies enables enhanced flexibility, improved quality, and increased productivity, making the hybrid model truly the best of both print worlds.

Hybrid print can reduce set-up time and costs while enhancing efficiency and productivity. These are some of the main reasons Document Data Solutions (DDS) manufactures and sells customizable inkjet print modules for use on offset presses, in addition to our comprehensive stand-alone web printing solutions. A DDS hybrid solution gives customers the option of adding high quality, personalized messaging and graphics in full CMYK color or monochrome, including spot colors, to their existing analog printing press, at speeds up to 1,000 feet per minute (fpm).

Overall, the hybrid printing market is projected to nearly double to more than $10 billion (USD) globally over the next four years, from $5.5 billion in 2024 (that’s a CAGR of >13%). By 2030, the figure could reach nearly $15 billion, according to forecasts from market research firms Markets and Markets and SNS Insider, respectively. Three major factors are driving hybrid print’s robust growth:

  1. The demand for shorter run lengths.
  2. The proliferation of high-quality printing in labeling and packaging applications.
  3. The continued adoption of personalized printed materials.

DDS print solutions are driven by a proprietary controller and layout designer software. The included layout designer software allows users to create print jobs and share resources through a centralized network database. Freedom Series™ printers are available with a variety of printhead technologies, resolutions, and drop sizes, each providing ultra-sharp image resolution.

These high-resolution inkjet printers provide versatile, cost-effective solutions that meet the need for variable data output on a range of coated and uncoated substrates. Capable of printing text, addresses, barcodes, 2D codes, QR codes, numbering, logos, and graphics, the Freedom Series print modules are suitable for mailing and addressing applications and labels, tickets, numbering, plastic cards, and business form applications.

A compact footprint makes our print modules quick to integrate into mailing or card lines as well as web printing applications. The modular design is simple but solid: We house all critical components within the print module and ink-delivery system, which makes for fast, easy installation. The system also features straightforward operation and maintenance. At startup, it’s ready to print within five minutes; job changeovers are possible literally within seconds.

Controlled Printing
DDS created advanced software to give customers greater printing capabilities. The iDataPrint Controller is a Microsoft Windows application that loads jobs created in the Layout Designer and manages the inkjet printing system. iDataPrint features include:

  • System Supports Various Workflows – PDF, IJPDS, CSV, Read and Print
  • Automatic Print Job Loading – With the handheld barcode scanner connected, iDataPrint can automatically load print jobs by scanning a Job ID barcode.
  • Control External Devices – We can configure iDataPrint to send I/O signals for many events. Examples include turning on an enunciator or performing more complex tasks, such as controlling an inserter or other equipment.
  • Live Assistance Available – If a user needs any help, they simply click “Live Assistance” from the built-in Help menu. A representative will be online with support in a matter of seconds.

An in-house team of software programmers keeps the DDS controller software up to date and continuously adds new features. By combining the strengths of offset and inkjet printing technologies, businesses can optimize production costs, decrease waste, and achieve a favorable balance between quality and expense.

Hybrid printing’s flexible agility seamlessly toggles between technologies, catering to a wide range of applications from commercial printing to packaging and labels. The ability to customize imagery and messaging, according to specific requirements, can position hybrid print as a preferred choice for organizations seeking a competitive edge in the marketplace.

 

Service-in-seconds™ is our secure, HIPAA compliant service that we created to give our customers the fastest service possible to resolve any issues and keep them in production. This service is available Monday through Friday from 8:00 AM to 5 PM Eastern. From any of our systems you can go to “Help” on the menu bar at the top of the screen and click “Live Assistance”. One of our technicians will connect with you and help resolve your issues.