CHALLENGE

In June 2021, Black Book Publishing began shutting down its Georgia-based offset print facility and sought a partner to handle the monthly production of 20,000 periodicals. The legacy workflow used preprinted address cards and regional cover versions, which added complexity and material handling. Black Book needed a reliable print partner to transition to digital production without disrupting schedules or quality. After launch, a major issue surfaced, periodicals were frequently delayed or lost within the USPS network, with pallets stalled for days or weeks and no clear resolution path.

SOLUTION

Sir Speedy Whittier was selected to manage the transition. The team consolidated internal workflows and reengineered the mailing process to eliminate address cards, instead printing the address directly on the back cover. To simplify regional versioning, a region number was added below the address line using variable data programming, allowing all versions to run in a single print stream. Periodicals were produced on lightweight paper using a high-speed continuous feed inkjet press, balancing cost efficiency and quality.

As USPS delays persisted, Sir Speedy Whittier embedded Apple AirTags into select books on outgoing pallets. This temporary tracking method provided real-time visibility and allowed Sir Speedy Whittier to work closely with USPS to identify bottlenecks and ensure the periodicals were properly handled. The AirTags were used until USPS implemented a system to reliably process and route the mailings.

RESULT

The program went live January 1, 2022. Results included:

• Full migration from offset to digital production.
• Streamlined addressing and cover workflows, reducing labor and material costs.
• Reliable, scalable monthly output of 20,000 books.
• Improved USPS delivery performance through direct coordination.
• Cost-effective mailing enabled by lightweight stock and optimized format.

This partnership gave Black Book a modern, agile print solution while resolving complex distribution challenges with a proactive and innovative approach.

CASE STUDY

Categories: BOOK MANUFACTURING 
Client: Black Book Publishing