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Craig, I'm Not sure how 4 cartridges a week =$2560 / month or 4 cartridges a month = $640 is irrelevant. Unless your on a click charge for ink, Is that available for these?

is the bad drawer defined as thinner paper or lighter GSM?

I've used lots of different desktop lasers and inkjets for envelops. Even ones with envelope fusers and feeders, and have lots of "Boy I'll never do that again" results. The biggest single factor is the envelope itself! Good quality new laser compatible will go through any of them. The envelope...

You may want to investigate automation see this discussion. https://printplanet.com/threads/best-solution-for-building-automation.291973/#post-309024

Are the items the same? Print the first one from acrobate, high lite the remaining files in the folder and right click print, from windows they will open and print using the same acrobat settings. I believe even the quantity caries in. I would think thtis could be done by a batch file too.

"I'm not that advanced to be honest. I'm just viewing the prints under a desk lamp. It is a strong one, I guess." Then "I guess" the print will match - lol

exactly what stock are you using? Perhaps someone on here uses it also. I know you use multiple brands right? Let us narrow it down a bit.

I have a pro7210sx and its better than all 3 previous canons I've had. the paper catalog was my biggest learning curve. I was learning the 8100 at the same time (replaced 2 machines in one deal) the m weight and finish are critical to ricoh IMO.

How are you creating/defining the paper in the catalog or are you manually setting it?

I'm surprised the other suppliers wouldn't have this feature available. A quick google of your controller and "overlay printing" lead to this video on a konica minolta. maybe it will help? good luck

Fiery VDP can do this. The guts are the master and the cover file would be the only variable page using the enhanced freeform to define/map variable to page 1. I use the setup quite often.

I've never tried using the define record length without a master and veriable file defined. I may play around with that but I know creating a master and naming the big file as veriable will work.

treat it like a multi page variable printing job. The Master (this time is blank) controls the folding with 4 pages pulled for the 2500 page doc. I do this for tax forms every year.

Design for productablity! Learned it in collage and love it to this day.

I in no way referenced the similarity to the usps first class tote bins I get in as supplies for my mailing use ONLY! -- wink

https://www.uline.com/Product/Detail/S-133W/Totes-Plastic-Storage-Boxes/Space-Age-Totes-18-x-13-x-12-White?pricode=WB0721&gadtype=pla&id=S-133W&gclid=Cj0KCQjwzLCVBhD3ARIsAPKYTcQbOCN274tX2qxXenab9EfFEcKP5cFKylELts3u7K0Sfu-FAduOLXgaAo2AEALw_wcB&gclsrc=aw.ds

Can the Head be retro-fitted to an existing inkjet base?

my 7210 runs it either way and duplexes 16pt every day. What drawer are you using and what finisher do you have?

How do the inkjets clean the "excess" or will it build up like a press?

Based on my canons; back side voltage adjustment, would cause/cure that. I would change it based on the weather/humidity change too.