The Print University header

Inside the Print Shop: Direct Mail Printers

Inside the Print Shop: Direct Mail Printers

Inside a Print Shop: Direct Mail Printer – Episode Summary

In this episode of The Print University, Pat McGrew and Ryan McAbee open the doors to a direct mail print shop—where regulatory precision, mailing logistics, and customer segmentation shape every aspect of production. Unlike general commercial printers, direct mail operations are intertwined with national postal systems, strict timing requirements, and data privacy laws, making them a critical focus for printing industry training programs for new employees and outsourced training for print production staff.

The hosts explore the diverse client base served by direct mailers—ranging from political campaigns and brand marketers to local tire shops—and how those clients rely on formats like postcards, catalogs, magalogs, and letters. Timing is paramount: every mailpiece must drop on schedule for campaign effectiveness. The episode introduces USPS programs like Every Door Direct Mail (EDDM), address hygiene standards (CASS), and tracking mechanisms using IMB barcodes.

Pat and Ryan also highlight technical requirements, including inserting and mailing equipment, hybrid print workflows (shell vs. white paper factory), and variable data capabilities—crucial for personalized campaigns. Listeners will learn about comingling, householding, and postal discounts, as well as how workflow automation reduces labor and improves audit performance. The discussion concludes with opportunities in multi-channel communication (print + digital) and sustainable hybrid mail solutions.

For any print team navigating direct mail complexity—from postal compliance to customer ROI—this episode delivers a front-row seat.

You Will Learn:

  • Unique challenges of direct mail print shops: timing, tracking, and compliance

  • Key terms: Every Door Direct Mail (EDDM), white paper factory, CASS, IMB

  • How inserting, overprinting, and hybrid print workflows are used

  • Techniques like co-mingling and householding to lower costs and increase efficiency

  • Direct mail’s role in multi-channel and hybrid communication strategies

Who This Course Is For:

Mailing specialists, variable data operators, print schedulers, compliance managers, and anyone training on digital printing press training, MIS software training for print production, or lean manufacturing training printing industry

Time to Watch:

Approx. 24 minutes