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.

2023 promises an interesting ride for print in India

Indian Printer and Publisher founded in 1979 is the oldest B2B trade publication in the multi-platform and multi-channel IPPGroup. While the print and packaging industries have been resilient in the past 33 months since the pandemic lockdown of 25 March 2020, the commercial printing and newspaper industries have yet to recover their pre-Covid trajectory.

The fragmented commercial printing industry faces substantial challenges as does the newspaper industry. While digital short-run printing and the signage industry seem to be recovering a bit faster, ultimately their growth will also be moderated by the progress of the overall economy. On the other hand book printing exports are doing well but they too face several supply-chain and logistics challenges.

The price of publication papers including newsprint has been high in the past year while availability is diminished by several mills shutting down their publication paper and newsprint machines in the past four years. Indian paper mills are also exporting many types of paper and have raised prices for Indian printers. To some extent, this has helped in the recovery of the digital printing industry with its on-demand short-run and low-wastage paradigm.

Ultimately digital print and other digital channels 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. For instance, there is no alternative to a rise in textbook consumption but this segment will only reach normality in the next financial year beginning on 1 April 2023.

Thus while the new normal is a moving target and many commercial printers look to diversification, we believe that our target audiences may shift and change. Like them, we will also have to adapt with agility to keep up with their business and technical information needs.

Our 2023 media kit is ready, and it is the right time to take stock and reconnect with your potential markets and customers. Print is the glue for the growth of liberal education, new industry, and an emerging economy. We seek your participation in what promises to be an interesting ride.

– Naresh Khanna

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