Case Study: How One Print House Increased Efficiency with Pre-Fab Media

That’s why more print houses are adopting pre-fab media — digitally printable substrates that are pre-coated, pre-cut, or pre-backed to streamline the production process. And the results? Faster turnarounds, less waste, and tighter workflows.

Here’s how one mid-sized print operation transformed their daily output — simply by switching to the right substrates.

The Challenge: Too Much Time on Prep

The company — a busy signage and retail graphics provider — was producing 50–60 jobs per week, including:

• Store window graphics

• In-store point-of-sale displays

• Wall coverings and floor decals

• Rigid boards for trade shows

Despite having the right equipment, they struggled with:

• Manual substrate prepping (surface cleaning, priming, or trimming)

• Frequent test prints due to adhesion or ink drying issues

• Delays in mounting and laminating steps

• Inconsistency between jobs based on staff handling

The team knew something had to change — especially as demand increased.

The Solution: Switching to Pre-Fab Media

After reviewing their most common jobs, the print house worked with a substrate supplier (found via Substrate Bank) to identify pre-treated materials optimized for their UV and latex presses.

They switched to:

• Pre-coated rigid boards for direct-to-substrate UV printing

• Self-adhesive vinyls with air-release liners to reduce install time

• PVC-free, flame-rated wallcoverings that required no lamination

• Pre-cut magnetic sheets for retail campaigns

These substrates were ready to print right out of the box — no prep, no priming, no fuss.

The Results: Faster, Cleaner, More Profitable

Within two months, the switch to pre-fab media resulted in:

• 20% faster job turnaround

• 30% reduction in setup time across jobs

• Fewer reprints and less waste due to consistent performance

• Lower labor costs with simplified installation

• Better client satisfaction due to improved delivery times

Most impressively, the shop was able to take on more last-minute jobs without disrupting scheduled work — giving them a competitive edge in a fast-moving market.

Key Takeaways for Other Print Providers

• Pre-fab media is not a luxury — it’s a workflow asset

• Time saved in prep and post-processing = direct margin gain

• Ready-to-print materials help new operators get up to speed faster

• Compatibility and certifications are crucial — always test before scaling

• Tools like Substrate Bank help identify materials by performance spec, certification, and application type

Conclusion: Less Prep, More Print

Efficiency in digital print isn’t just about having the right press — it’s about choosing substrates that work with your workflow, not against it. Pre-fabricated, pre-treated, and ready-to-use substrates help print providers streamline operations, reduce bottlenecks, and increase output without adding stress.

Because in today’s print environment, every minute — and every material — counts.