Automated File Routing: The ZenSmart Solution for the challenges of print on demand

Automated File Routing: The ZenSmart Solution for the challenges of print on demand


In the print-on-demand industry, especially among smaller printing facilities, a key challenge remains: manual file routing. This practice, still common in 2023, involves multiple manual steps – from retrieving order files to copying them into imposition suites, then moving them to the press hot folder. Each step, typically performed by humans, is a potential source of error and file movement risks, which can lead to material wastage and inefficiency.

The Problem of Manual File Routing

Consider a typical scenario: an order arrives via email or web-to-print systems. A staff member, such as a salesperson or production team member, downloads these files from platforms like Dropbox or Google Drive. They then place these files into an imposition system with other “similar output” files.

This manual process is prone to errors, from batching mistakes to incorrect folder placements, often resulting in costly reprints and labor wastage.

The Limitations of Existing Automated Solutions

Current automated file routing solutions exist, but many are basic systems relying on accurately named files (often a manual task) and simply transfer files from one point to another. These systems typically have rigid workflows and limited capabilities. They might automate some parts of the process, such as moving files post-imposition, but often do not cover the entire workflow.

ZenSmart’s Comprehensive Approach

ZenSmart addresses the complexities of automated file routing effectively.

Here’s how:

  • Automated File Retrieval and Storage: ZenSmart automatically retrieves order files, storing them with a unique naming convention in the ZenSmart file archive. It handles various protocols and formats and retries in case of failures, ensuring no file is missed.
  • File Validation and Conversion: Utilizing MD5 technology and proprietary checks, ZenSmart validates each file, converts formats, counts pages, creates thumbnails, and generates metadata for reporting and system use.
  • Seamless Press Submission File Movement: ZenSmart collates files from the archive, merges them into the chosen imposition template, and moves them to the press hot folder efficiently.

The Benefits

Implementing ZenSmart significantly reduces manual errors and improves efficiency.

The time from order placement to printing is reduced, leading to a smoother, quicker, and more reliable printing process, with lower material wastage.

In a market where speed and accuracy are crucial, ZenSmart offers an effective automated file routing solution that reduces costs. It demonstrates the potential of intelligent software to improve traditional processes in the print on demand industry.

Interested in Learning More?

For more information on how ZenSmart can enhance your printing workflow, visit .

Sammy Brent

Sammy Brent is the CIO of ZenSmart, a leading workflow automation platform that streamlines manufacturing in On Demand plants across the world.



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