Why not consider adding robots to your operation to relieve operators from repetitive tasks and the strain associated with them?
After your list, your direct mail design strategy is critical. Your images, layout, fonts and colors all matter.
Slowing down and following a "Best Practices" method to paper trials and qualification will save you time and ink costs by focusing on ink and paper surface compatibility. As your cost for a better inkjet paper and print quality go up, your ink usage should go down. But only if there are best practices in place.
The fifth housing station in the upgraded Xerox 800i/1000i series can now also deliver metallic inks: gold and silver.