In an industry where margins are tight and competition is fierce, finding smart ways to reduce printing costs is a must. As we step into 2025, print businesses must rethink their operational...
Commercial printing is extremely competitive and every inefficiency chips away at profitability.
While manual job processing might seem manageable on the surface, its hidden costs often create roadblocks to scaling your print business effectively.
With over 20 years in the print industry, the Print ePS team has encountered many businesses that suffer from labor-intensive workflows and manual processes which increase errors, silently drain your resources and ultimately, stunt growth.
In this article, we explore the hidden costs associated with manual job processing and offer actionable tips on how to eliminate them using automation and productivity tools, paving the way for a high-performance, future-proof print business.
Contents
- The labor drain
- The price of human error
- Missing the advantage of speed
- Losing control over operations
- Rising material costs
- Stalling business growth
- Ready to build a high-performance print business?
The labor drain
Manual job processing often involves repetitive tasks like order intake, quoting, prepress setup, and scheduling. These activities demand significant labor hours, which could be better spent on high-value activities like strategic planning or customer engagement.
The cost:
- Wasted time on repetitive tasks
- Higher labor costs due to inefficiency
- Limited capacity to handle more jobs
The solution:
According to Willis Towers Watson, 57% of employers want to use automation to improve human performance and productivity.
This reflects the growing recognition of how automation can transform efficiency and free up valuable employee resources.
Automation reduces the need for manual intervention in job processing. Print management software enables streamlined workflows, freeing your team to focus on value-added services. With fewer hours spent on mundane tasks, labor costs decrease while productivity improves.
The price of human error
Humans are prone to error, and in manual job processing, even small mistakes can have significant consequences. Whether it’s a misquoted job or incorrect material selection, these errors lead to wasted resources, missed deadlines, and dissatisfied customers.
The cost:
- Job rework expenses
- Wasted materials
- Damage to customer trust and brand reputation
The solution:
Printing Impressions reports that the average printer’s net profit margins are between 1-3%.
In such a tight-margin industry, even minor errors can erase profitability.
Implement print estimating and quoting tools, like iQuote to ensure consistent and accurate pricing. Automation minimizes manual data entry errors and ensures proper material allocation, reducing costly mistakes and maintaining customer confidence.
Missing the advantage of speed
In a world where fast turnaround is king, manual job processing can slow down operations. Delayed approvals, redundant communication, and inefficient scheduling create bottlenecks that frustrate customers and result in lost opportunities and revenue.
The cost:
- Missed deadlines
- Lost business to faster competitors
- Reduced customer satisfaction
The solution:
Statista reveals that 84% of company representatives believe AI can bring competitive advantages to their industry.
Leveraging AI-driven scheduling tools can be a game-changer for print businesses looking to outpace the competition.
Advanced print scheduling software, such as PrintFlow 4D, can optimize your production timelines by proactively managing resources and equipment. This allows for faster job completion, meeting even the tightest deadlines with ease.
Losing control over operations
Manual processes often operate in silos, leading to poor visibility into real-time job statuses. Without comprehensive oversight, it’s challenging to identify inefficiencies or make informed decisions to improve operations.
The cost:
- Reactive management practices
- Inefficient resource allocation
- Missed opportunities for process improvement
The solution:
Shop floor data management tools, like Auto-Count 4D, offer real-time insights into your operations. These systems track job progress, identify bottlenecks, and provide actionable data, enabling you to make informed decisions and maximize efficiency.
Rising material costs
The print industry faces rising costs for paper, ink, and energy, making waste reduction more critical than ever. Manual processes often lead to material overuse, unnecessary waste, and inefficient procurement practices.
The cost:
- Increased material expenses
- Lower profit margins
- Inefficient use of inventory
The solution:
Integrating material tracking and cost analysis tools into your operations helps optimize material usage. Print layout and planning solutions improve press utilization and reduce waste by creating accurate, data-driven layouts.
Stalling business growth
“In order for a business to scale, it has to improve efficiencies. Efficiency is a prerequisite for sustainable scaling.” – Hendrith Vanlon Smith Jr.
Manual processes can’t keep pace with growing demand. As your business scales, the inefficiencies of manual job processing become amplified, limiting your ability to take on new opportunities or expand services.
The cost:
- Inability to handle higher volumes
- Higher operational overhead
- Missed revenue opportunities
The solution:
Scalable automation solutions grow with your business, enabling you to handle more jobs without proportional increases in labor or overhead. Modular tools let you start small and add features as your needs evolve, ensuring long-term growth and profitability.
Ready to build a high-performance print business?
Eliminating the hidden costs of manual job processing starts with adopting the right tools. Modern print productivity solutions integrate seamlessly into your operations, providing automation, real-time insights, and scalability. By streamlining workflows and reducing errors, these solutions empower you to focus on delivering value to customers and driving growth.
The challenges of manual job processing are just one piece of the puzzle. To learn more about creating a high-performance, future-proof print business, download our comprehensive eBook: “Building a High-Performance Print Business.”
In this guide, you’ll discover actionable strategies to address key industry challenges—from managing costs and embracing automation to diversifying services and ensuring sustainability.
Download the eBook and take the first step toward transforming your print business.
