Between 2003 and 2005, mailing production is further expanded. Mailings are now produced using multiple inkjet personalisation units and two Pitney Bowes Post Star Vitesse inserting machines with four and six stations respectively. A custom-built mailing system enables inline folding, personalisation, application of response elements, gluing and perforation in a single process step, enabling efficient production of self-mailers. Annual output increases to more than 10 million mailings.
A new digital printing department is established with an OCÉ CPS 900 (7-color) and an OCÉ VarioPrint 2100 (both black-and-white systems). These digital presses are primarily used in mailing production, either for monochrome laser personalisation of offset pre-printed sheets or for fully colour-personalised digital mailings. In addition, both black-and-white systems enable entry into the print-on-demand segment. Small print runs such as books, brochures, business cards, flyers and A3 posters can be produced quickly, flexibly and cost-effectively.
In print finishing, equipment includes a Heidelberg Quickfolder (for small formats and short runs up to A3), a Stahlfolder TD78 Topline 6/4/4 with pallet feeder, and a GUK FA52 6/4/4 with flat pile feeder, special creasing unit and two suction belts. Cutting is performed with a Heidelberg Polar 115, while saddle-stitched brochures are produced using a Müller Martini saddle stitcher with eight stations plus cover feeder, card inserter and cross stacker.