Digital Printer, December 2009

PHD MAIL GOES TRANSPROMO
Investment in new software, printers and finishing equipment has helped PHD Mail to double its turnover in recent months. Simon Ecclesfinds out how it’s been done.

PHD Mail in Burton-on-Trent is a heartening success story for digital in the recession. Its monthly turnover has doubled since the

summer and it saw its best month ever in September, taking £470,000. Business development director Kevin Dunn says the company is likely to hit £5.5 million by its year end next August.

These healthy figures come in part on the back of investment in new equipment that’s allowed the company to introduce new services. It now offers monochrome transpromo to its customers following the adoption of three InfoPrint 2235 cut sheet digital printers, with InfoPrint Workflow and GMC PrintNet T Designer front end software. These replace a set of ten year old Xerox 4635 printers that were worn out, and join eight reel-fed InfoPrint 4000/4100 monochrome units and three InfoPrint 2000 cut sheet models dating to 2002, when InfoPrint was still the IBM Printing Systems division.

New mailing equipment, including a Pitney Bowes Olympus 2 sorter, has allowed it to aggregate several smaller jobs, allowing PHD to offer mail sorting services to companies whose run lengths wouldn’t have previously qualified for Royal Mail discounts.

PHD Mail was set up in 1990 and handled direct mail until 1998. Mr Dunn started in late 1998 and was part of the move away from direct mail to transactional billing. ‘Direct mail was too cut-throat – people would move for £1 per thousand difference,’ he said.

Today the main print work is billing, statements, final demands and the like, with additional online services to clients that including web hosting and e-billing. ‘Web hosting allows archive retrieval of invoices and statements, so customers can send them to their customers as e-mail attachments instead of posting copy invoices. It’s a lot quicker and easier than manual retrieval,’ said Mr Dunn. A pair of £55,000 Kodak 1860 high speed scanners are used for document entry.

‘Our market is short run, but daily,’ Mr Dunn explained. ‘We may do 4000 envelopes, or some customers send us 150 bills. These runs are too small for the likes of RR Donnelley or Communisis. ‘A lot of the printing is white paper – about 60%. But we do also print on pre-printed letterheads or bill – it’s still cheaper to do that than white paper colour.’

The combination of the higher quality of the new machines with the new GMC software has allowed PHD to start offering transpromo, where promotional messages are printed alongside the billing and statement information. So far this is still being introduced to clients, but 12 of them are using it already.

The type of work ranges from simple promotions to complex multiple ads for different geographical regions, says Mr Dunn. ‘We have a telecoms client that ads a message that says ‘you have x points this month and here’s how to redeem them.’ Another client has an ad panel that changes from month to month.

Another idea is to base the message on what a client has bought recently – if they buy a hammer, it may show screwdrivers for instance.

‘We’ve got the software for processing the data. Since we’ve bought the GMC PrintNet we’ve shown customers that we can drop an ad in and change it on the fly two days before going to print. They like it and are getting the marketing guys onto it. GMC has been very helpful to us, especially in the early days.’

This is all monochrome work. The company has also put in a 45 page per minute Ricoh 1767 colour printer, but this is a light production machine that it wanted mainly for development work. Mr Dunn doesn’t think full colour transpromo will attract his client base, mainly on cost grounds. ‘We don’t think we will be able to get people to pay the sort of extra money that colour will cost. We can do mono transpromo for £15 per thousand, but colour would be £45, so it’s harder to sell.’

Belt and braces
The company runs two separate sites in the Burton-on-Trent area, identically equipped so production can continue if one is knocked out of action. ‘Every six months we shut the primary site down for three days and switch to the other,’ Mr Dunn explained. ‘Meantime we keep it warm and rotate jobs between them. It’s a nice set-up, it cost us a lot, but it does instil confidence in the clients.

There are 54 employees, 80% working in production with the rest including five IT developers, four data processors and the rest being office and accounts staff. Production runs in two shifts, six days per week. This highlights a particular benefit of the new InfoPrints, Mr Dunn says: unlike the old Xerox models they can be switched off at night. ‘We reckoned that the InfoPrints would save £7000 pa on electricity bills alone,’ he said. ‘They should also be easier to maintain.’

He says that serious consideration was given to buying new Xeroxes, with the big Continua agency offering ‘a really good proposal.’ But in the end InfoPrint won the deal because of PHD’s favourable experience with the earlier sheet and reel fed models. ‘We already had InfoPrints and the company always looked after us well’ he said.

On the finishing side, the past three months has seen the company install a Pitney Bowes Olympus II MT multi tier mail sorting machine with 128 sorting pockets, alongside an existing Kern 2500 Multichannel envelope inserting line with eight stations.

Mr Dunn is particularly pleased with the Olympus: ‘It’s a fantastic machine, one of the best investments we’ve made. Because we do short runs, some clients fall below the minimum of 4000 needed for mailsort. So we can combine jobs to get above this, and then pass the savings on to the clients. It’s helped us to win more business.’

Some mailing systems incorporate inkjet addressing heads, but we don’t need those, Mr Dunn says. ‘All sheets go into window envelopes so the addresses show through. We used to have inkjets for direct mail but I sold them all. I’ll never go back to direct mail!’

What’s an InfoPrint 2235?
The three InfoPrint 2235 printers at PHD Mail are 135 page per minute monochrome toner machines with a duty cycle of 1.9 million A4 pages per month (two-up on A3 sheets). They are the fastest in the series, which also includes the 2190 (90 ppm) and 2210 (110 ppm). They are based on Kodak engines with InfoPrint front ends, service and support. The resolution is 1200 x 1200 dpi. These printers can be fitted with up to seven paper sources for a total of 8050 sheets. Standard fitment is one 1000 sheet tray and two 500 sheet trays. There’s an additional choice of three-tray A4 or A3 high capacity feeders for 4550 or 4000 sheets respectively: PHD Mail has a selection of both sizes. In-line options include ring binding, Z-folding, saddle stitch booklet making and perfect binding, although PHD Mail doesn’t need these. InfoPrint supplies user replaceable parts and training, so operators can do routine maintenance and some repairs without an engineer callout. They can take multiple data stream input, including InfoPrint native IPDS, InfoPrint RPCS, PostScript and PCL 5e/6. Contact: www.infoprint.co.uk

GMC PrintNet T Designer
GMC is one of big names in enterprise level document management. Its software tools cover personalised document creation for print or electronic output, process automation workflows, and web-based collaborative workflows. PrintNet T Designer is intended for creation and production of personalised direct marketing and transaction documents (including transpromo), for on-demand output. PHD Mail runs it on an AIX platform but it’s also available for Macintosh, Solaris and Windows platforms. It looks much the same as a desktop layout program in operation. Complex rules-based applications can be set up, with no need for programming skills. This is helped by debugging tools for general processing, scripts and job flow. It can import static designs and text from standard programs such as Adobe InDesign or QuarkXPress, MS Word (including RTF), PDF documents and XML. These are then modified for flowing in personalised variable data from multiple sources such as address lists, transaction records or code tables. It automatically assembles all design, data and other document resources, and sends them as composed files to the printer or other delivery channel. Contact: www.gmc.net