Precision Mail Inserters Drive Growth at D4 Solutions
In a fast-paced, highly regulated market where technology evolves rapidly, standing still is not an option. For Angelica Kemlage, President and CEO of D4 Solutions, a new opportunity sparked a bold initiative: to explore more sophisticated technology that could deliver greater value through measurable gains in productivity and enhanced document integrity—for both D4 and its customers.
Formerly known as ComGraphics, D4 Solutions is an employee-owned company with deep roots in the variable data printing and electronic document solutions space. Founded in 1980 and rebranded in 2022, the company operates from an 85,000-square-foot, state-of-the-art facility in Addison, Illinois. With operations running 24/7, the company serves a diverse clientele in industries where accuracy, compliance, and speed are mission-critical—including financial services, insurance, healthcare, government, and direct marketing.
From transactional mailings to performance reports, letters and pressure-sealed mailers, D4 Solutions delivers customized communication solutions with precision and reliability. Now, the company was ready to take its capabilities to the next level with the help of a key partner, MCS Inc., a firm that designs, manufactures, sells, and supports industrial inkjet imaging, tracking, and inserting systems and solutions for the mail manufacturing industry. With thousands of systems installed in the mailing and marketing industries across the world, MCS equipment has been used for mission-critical mailings, including vote-by-mail for government agencies.
“Our relationship with MCS has contributed to the growth and evolution of our business. They’ve offered support and solutions that expanded our capabilities. They are a trusted partner, vendor, and key part of our continued success,” says Kemlage.
D4 Solutions has worked with MCS since 2020, when they explored ways to improve the company’s Service Level Agreements (SLAs) and deliver better service to their clients. SLAs, common in highly regulated industries, IT, customer service, logistics, and manufacturing, establish measurable performance standards and clearly outline the responsibilities of both client and vendor.
In the early stages of the relationship, however, MCS equipment had not yet been integrated into the production environment. At the time, D4 Solutions relied on swing-arm inserters, machines often used in high-volume operations like direct mail that use a vacuum mechanism to hold inserts in place and ensure precise placement into envelopes.
The challenge was that, in a time-sensitive environment, the lack of advanced automation created constant pressure. Slower equipment made it difficult to meet deadlines, scale operations, and respond quickly to client requirements.
“We recognized the urgent need to increase operational speed. Enhancing the technology behind the inserting process and improving machine throughput were critical to consistently meeting service level agreements. This prompted a thorough evaluation of available solutions,” says Kemlage.
Although the swing-arm inserters were adequate at the time, the machines could no longer keep up as D4 Solutions’ service volumes substantially increased. Additionally, clients were demanding more detailed tracking and greater visibility in their mailings, according to Kemlage.
"We evaluated various options on the market, but the deciding factor for us was the level of support we received from MCS. We switched from the older swing arm machines to the [Mailstream Evolution (MSE)] systems for speed and reliability. The equipment also provides internal tracking capabilities that weren’t available with the swing arms,” says Kemlage.
Through MCS, the company selected four high-speed Mailstream Evolution systems from BlueCrest (formerly Pitney Bowes DMS), a world leader in mission-critical envelope inserting solutions. The MSEs, high-speed inserting systems designed to precisely handle complex high-volume mail processing, automate the entire mail assembly process. This includes feeding documents, inserting into envelopes, and sealing the mail pieces—all while maintaining strict accuracy standards.
The systems support inline printing and personalization of envelopes and include built-in tracking features such as barcode scanning and camera verification to ensure each piece is processed correctly. This level of control and automation makes the machines especially well-suited for environments where compliance, data integrity, and operational efficiency are critical, such as transactional mail operations in finance, healthcare, government, and service bureaus.
MCS, with over three decades in mail manufacturing, understands customer needs and application challenges. This expertise, supported by a strong service team, enables the company to enhance products from other manufacturers when it brings unique value to the market. As an example, MCS adds tracking and inkjet technology to BlueCrest inserters to make them more adaptable for direct mail manufacturers.
“With our current technology, we’ve not only reduced our internal costs but also increased our trust with customers. We’re better equipped to meet key performance indicators and conduct deeper data analysis,” says Kemlage.
According to Kemlage, D4 Solutions’ relationship with their vendor has evolved to encompass far more than equipment purchasing.
“MCS has become a trusted partner. They’ve helped us network, expand our services, and find vendors to resolve challenges. As a result, we’ve grown our business and improved our bottom line,” says Kemlage.
Today, D4 Solutions has further expanded its data-driven services for clients in regulated industries, with a strong focus on data security. Its in-house programming experts work with nearly any file type to turn complex data into secure, usable communications.
With Kemlage’s leadership, the company continues to actively invest in technology to enhance security and document integrity, keeping the company ahead of industry demands.
For a video highlighting D4’s story, visit https://mcspro.com/mcs-video/d4-success-story.
The preceding press release was provided by a company unaffiliated with Printing Impressions. The views expressed within may not directly reflect the thoughts or opinions of the staff of Printing Impressions.
