Tecnau leaves a lasting impression on DFS

DFS (Document Fulfillment Services) case study

Tecnau leaves a lasting impression on DFS

Transitioning from one printer technology to another can often be intimidating. It is particularly important for printing companies, like DFS, to make the right choice. The company prints transactional documents such as bank statements and tax forms that include critical information. Daniel Chavez, chief operations officer and a DFS employee since the company’s 2002 inception, decided three years ago to take on the major challenge of upgrading its printer technology. DFS switched from a cut sheet printer operation to an inkjet continuous printer platform. This technology change not only included a new inkjet printer but also the Tecnau Stack 2020 and its Dynamic Perforator TC 1550.

The first step in making this transition involved selecting a print provider. Before making this key decision, Chavez looked at just about every supplier in the market. The runner up in the initial investigation, Screen Americas, proposed a full-maintenance plan for the press and self-maintenance plan for the finishing line. “The self-maintenance program was a big concern. I just wasn’t ready to be in the service industry,” stated Chavez.


However, Chavez ultimately decided that the Screen offering, the Truepress Jet520 NX, was right for DFS while still including the Tecnau Stack 2020 finishing line offered by the early favorite press vendor. The new Tecnau/Screen solution was up and running within one week. “With a reliable print engine and the Stack 2020, we gained a five-fold increase in speed. We went to 18 inch rolls, printing on both sides with a slit merge, and ending up with an 8 ½ inch X 11 inch finished product. It was just amazing,” declared Chavez.

Once DFS transitioned to the Screen solution, it indeed moved to a self-maintenance environment for the finishing line, while the press was reliably maintained by Screen. Chavez promoted two of his best operators and converted their roles into hybrid positions. By following procedures, the equipment has been easily maintained, and issues have been nearly non-existent. The team has only had to deal with the normal wear and tear on parts. The company may be stocking more parts, but overall, it has worked out very well. It has resulted in a 30 percent savings over hiring an outside third-party vendor to service the equipment. “For someone who was so afraid to self-maintain the finishing, I am now eating my own words. To have more control has been very nice,” stated Chavez.


The Tecnau Stack 2020 has performed beyond DFS’s expectations. “It has been running 24 X 7 for 38 days straight. It is a real workhorse,” professed Chavez. Over 40 million 8 ½ inch X 11 inch sheets of paper have gone through the finishing line. It has become a critical line in the transactional space with over 100 million impressions and 12 million statements in one month. This level of output is made possible with the help of the Stack 2020 system’s Smooth-Web motion technology that gently transports paper from the printer to stacked output. This synchronization of the entire web to changes in speed provides unprecedented reliability and drastically reduces the likelihood of any paper jams.

Plus, Chavez considers the Dynamic Perforator TC 1550 “the Cadillac version of perforators.” DFS has used it for many different types of applications ranging from coupon books with multiple perforations and custom ID cards to single perforation bank and tax statements. According to Chavez, “Regardless of the number of perforations, the speed of the equipment is never compromised.”

Not only did the Tecnau equipment stand out from the competition, but also the Tecnau team stood out to Chavez. As he noted, “They do everything, which was promised in the sales pitch. The sales rep still called me regularly, even after the equipment was purchased and installed. His level of service was a key deciding factor when I selected Tecnau again.”


When replacement parts are needed, the Tecnau team is there to answer the phone. There is no texting or emailing and then waiting for a response. Parts are expedited without any hesitation. “This outstanding level of service just seems to be the Tecnau way no matter who you are calling within the organization. It has far exceeded my expectations,” stated Chavez.

In 2021, DFS plans to install a second line, which will include Tecnau equipment. “The Tecnau solution may not be the least expensive option in the market, but the company’s integrity and doing what they say has spoken volumes to me,” proclaimed Chavez.

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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– Naresh Khanna

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