Post on 25-Aug-2020
In-Plant Market
StatisticsA THOROUGH ANALYSIS OF TODAY'S IN-PLANT INDUSTRY
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METHODOLOGY
The names used for this survey were taken from In-plant Graphics' subscriber database. In December 2011, we e-mailed 14,370 readers/in-plant managers asking them to participate. We followed this up with two reminder e-mails.
When we closed the survey in January 2012, we had received 277 responses from managers/directors/supervisors of in-plant printing operations. The data in this report are based on a computer tabulation of the 277 qualified completed surveys that we received.
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IN-PLANT MARKET AT A GLANCE
Budget2012 Average: $2,293,7122012 Median: $887,500Average two years ago: $2,028,124
Employees2012 Average: 15.122012 Median: 7Average two years ago: 15.65
In-plant Funding
Self-supporting 39%
Services In-plants Provide n 2012 n 2010
Digital Printing/Copying 97% 96%
Bindery 96% 97%
Prepress 75% 79%
Graphic Design 73% 72%
Offset Printing 69% 75%
Variable Data Printing 62% 61%
Mailing 60% 59%
Wide-format Ink-jet Printing 59% 58%
Online Ordering/Job Submission 56% 65%
Print Procurement 47% 40%
Fulfillment 38% 37%
Scanning (for archival purposes) 38% 41%
Copier Program Management 35% 40%
CD/DVD Production 24% 29%
QR Code Creation 24% —
Photo Printing 22% —
Data Center/ IT Printing 18% 17%
Copyright Clearance 16% 18%
Selling Promotional Items 12% 13%
Photography/Videography 12% 13%
Web Site Design/Maintenance 9% 12%
Other * 9% —
Cross-media Marketing 8% —
Database Management 8% —
Engraving 7% 4%
E-marketing 5% 4%
Garment Printing 4% 3%
In-plant Funding
0 50 100
* Writing/editing, custom framing, lamination, padding, flex labels, education, address maintenance, faxing, braille printing, fine art reproduction, envelope manufacturing.
Funded 26%
Mostly funded, some revenue generation
16%
Mostly self-supporting, some budgeted funds
19%
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BUSINESS GROWTH
0 50 100
What In-plants Produce | Compared with 2008 figures, there has been a notable increase in in-plants producing business cards, stationery, posters, direct mail and annual reports.
n 2012 n 2010
Brochures 94% 96%
Newsletters 90% 91%
Business Forms 86% 86%
Pamphlets 82% 84%
Stationery 82% 84%
Business Cards 81% 85%
Posters 81% 81%
Reports 77% 77%
Envelopes 76% 77%
Manuals 74% 81%
Banners/Signs 71% 67%
Tags/Labels 69% 71%
Direct Mail Pieces 68% 73%
Calendars 67% 68%
Annual Reports 65% 68%
Directories 55% 62%
Bills/Statements 40% 39%
Pocket Folders 32% 36%
Magazines 27% 25%
ID Cards 26% 25%
Engineering Drawings 17% 18%
Point of Purchase 14% 14%
Photo Books 13% —
Packaging 12% 9%
Vehicle Wraps 5% —
In-plant Expansion | In-plants continue to expand in a variety of ways:
n Past 3 years n Next 12 months
Moving to a new facility 7% 7%
Adding space to facility 7% 10%
Increasing staff 11% 16%
Adding equipment 41% 70%
Adding services 37% 68%
Manager to oversee additional departments 10% 15%
Merging with mailing operation 4% 7%
Expanding mailing operation 8% 12%
Merging with data center/ IT printing operation 2% 3%
No growth 35% 13%
No new services 23% 10%
Reducing shop's size 8% 15%
0 50 100
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INSOURCING AND BEST PRACTICES
Growth in Insourcing | Taking in work from outside their organization has helped in-plants fill up idle equipment time, recover costs and pay for shop improvements.
• 72% say insourcing has strengthened their in-plant.
• 44% are providing revenue back to their parent organizations.
• 22% say insourcing has allowed their in-plant to add new equipment
• 8% say insourcing has allowed them to add employees.
• Just 7% say insourcing has created conflicts between their organization and outside entities.
Yes, we insource 53.4%
Growth in Insourcing
In-plant Best Practices
n 2012 n 2010
Charge back for printing/binding. 78% 81%
Compare our costs with outside printers. 72% 79%
Self-promotion/marketing of in-plant. 63% 63%
Report savings to upper management. 56% 59%
Provide education/training to employees. 30% 37%
Right of first refusal for all printing. 28% 28%
Market in-plant using social media. 9% — 0 50 100
Impact of Outsourcing | Facilities management firms have approached 46 percent of in-plants in the past two years, offering to take over their printing. Here are the results of those meetings:
The FM could not save the organization money. 59%
The FM could not provide all the services the organization required. 37%
Being challenged made the in-plant stronger, with improved services. 32%
The in-plant manager now has more responsibilities. 16%
The in-plant now outsources more printing/copying. 7%
All printing/copying will be produced by an outside firm. 3% 0 50 100
No, we don’t 46.6%
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OFFSET VS. DIGITAL
Offset, Digital or Both? | Though most in-plants handle both offset and digital, nearly a third are now all digital.
Offset and digital printing.68%
Four-color | Percentage of four-color pages produced via: Monochrome | Percentage of
black-and-white pages produced via:
Offset Presses 25.41%
Offset Presses 27.34%
Offset | Percentage of in-house offset printing that is: Non-offset | Percentage of
in-house digital printing that is:
Black-and-white 43.82%
Black-and-white 57.76%
O�set, Digital or Both?
Four-color
O�set
Monochrome
Non-O�set
Offset presses/duplicators only.1%
Digital printers/copiers only.31%
Digital Printers 74.59%
Digital Printers 72.66%
Multi-color 26.69%
Four-color 29.49%
Multi-color 10.6%
Four-color 31.64%
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NEW EQUIPMENT
Purchasing Plans | 67 percent say upper management supports their requests to upgrade equipment. About 41 percent plan to buy or lease new equipment in the next 12 months. Here's what's on their lists:
Bindery Equipment 29%
Digital Color Printer (30+ ppm) 22%
Design/Prepress Software 16%
Wide-format Ink-jet Printer 12%
Mailing Hardware 12%
Mailing Software 10%
Computer-to-plate System 7%
Offset Press 5%
No purchases planned 39%
0 25 50
0 25 50
Recent Upgrades | In the past two years, 81 percent of in-plants have added equipment or software. Here's what they installed:
Digital Color Printer (30+ ppm) 39%
Bindery Equipment 39%
Design/Prepress Software 26%
Wide-format Ink-jet Printer 25%
Mailing Hardware/Software 14%
Computer-to-plate System 13%
Offset Press 12%
Copiers
Average number of copiers/ multifunction printers used for in-plant production:
6.34
Average number of copiers/ multifunction printers in-plant manager is responsible for:
99.19
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VDP AND CTP
VDP On The Rise | More than 62 percent of in-plants produce variable data printing. They say an average of 15.23 percent of their digital print jobs contain variable data. Here are the types of variable information they print:
Address information (including bar codes) 89%
Recipients’ names (on the printed piece) 85%
Paragraphs of variable text 32%
Images 30%
Color (text or images) 27%
Personalized messages on envelopes 22%
Transpromo* 8%
Personalized URLs 6% 0 50 100
* Personalized promotional or educational messages printed on bills, statements, etc.
Computer-to-plate | Of those with CTP equipment, here are the types of systems they have.
Thermal Laser 22%
Visible Laser (e.g. Violet) 7%
Ink-jet Imaging 7%
Processless (Chemistry-free) 17%
Metal Plates 31%
Polyester Plates 28%
Do not use 37% 0 25 50
Are You Green? | Have you made changes in the past year to be more environmentally friendly?
Not really 27%
A few changes 29%
A lot of changes 12%
Major changes 2%
VDP Issues | • Many customers don't seem interested in VDP but prefer static printing. 49%
• Poor database management has been a roadblock to our providing VDP. 24%
• We have brought VDP ideas to customers to demonstrate what our digital presses can do. 48%
• Data security concerns have led to more VDP jobs for our in-plant. 9%
Are You Green?
More than 2 years ago 30%
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PAPER TRENDS
Shopping Around | Most managers rely on multiple merchants to get the best paper deals.
More than one paper merchant 74%
Office supply companies 18%
A single paper merchant 21%
Retail paper store 7%
Online suppliers 6
Direct from mill 6
Manufacturers’ paper sample books 4%
Other* 4% 0 50 100*State contract, bid process, paper converters
...Though their customers do not.
Always 43%
Always 3%
Brand Name Paper?
Most Popular Papers | Once again colored paper tops the list as the most common paper purchased by in-plants.
Cover 92%
Colored 87%
Bond 87%
Copier 84%
Coated 81%
Carbonless 80%
Index 75%
Uncoated 75%
Label 69%
Text 69%
Offset 66%
Recycled 64%
Laser 52%
Multiple-Use 50%
Premium 46%
Wide-Format 46%
Ink-Jet 21%
Synthetic 19%
Magnetic Material 17%
Roll-fed/Web 10%
Other* 3%
0 50 100* Permanent paper, Tyvek, security paper, C1S
In-plants often specify paper by brand name.
Paper customerPaper InPlant
Sometimes 28%
Rarely 47%
Never 22%
Sometimes 45%
Rarely 10%
Never 2%
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EQUIPMENT AND SOFTWARE AT IN-PLANTS
SoftwareDigital Storefront/Online job submission 38%
Shop Management (e.g. Estimating, Inventory) 50%
Workflow 42%
Proofing 31%
Color Management 39%
Design 71%
Imposition, Trapping, Preflighting 64%
Variable Data 53%
PrepressProofing 59%
Densitometer/Spectrophotometer 64%
Imagesetter 23%
Computer-to-plate (CTP) system 70%
PressesSheetfed Offset (up to 20˝) 84%
Sheetfed Offset (21˝ to 29˝) 35%
Sheetfed Offset (30˝ AND UP) 8%
Sheetfed Offset – One, Two-color 54%
Sheetfed Offset - Four-color or more 28%
Direct Imaging Offset Press 9%
Envelope Press (Offset) 17%
Envelope Feeder 39%
UV Coating 5%
0 50 100
0 50 100
0 50 100
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Digital Copiers/Printers
B&W Copiers/Printers (up to 80 ppm) 32%
B&W Copiers/Printers (81-99 ppm) 27%
B&W Printers (100+ ppm) 70%
Color Copiers/Printers (up to 40 ppm) 24%
Color Printers (41-99 ppm) 75%
Color Printers (100+ ppm) 20%
Digital Duplicators (e.g.Riso, Duplo) 11%
Wide-format Ink-jet Printers (20˝-36˝) 19%
Wide-format Ink-jetPrinters (37˝-60˝) 43%
Wide-format Ink-jetPrinters (> 60˝) 4%
Digital Envelope Press 11%
Bindery & Finishing
Collators 64%
Folding Equipment 97%
Saddle Stitchers 83%
Perfect Binders 34%
Double-loop/Spiral Wire Binders 35%
Paper Cutters 97%
Laminators (wide-format) 43%
Laminators (conventional) 59%
Drills/Punches 93%
Scoring/Slitting 71%
Addressing & Mailing
Mailing Software 62%
Ink-jet Addressing/Bar Coding Systems 51%
Inserters 61%
Labeling Systems 30%
Postage Systems 66%
Mail Sorting Equipment 24%
Tabbing Equipment 54%
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Editor:Bob Neubauer215.238.5321bobneubauer@napco.com
Publisher:Glen Reynolds215.238.5097glenreynolds@napco.com