Solving Manufacturing's Print and Output Management Challenges
Vasion Team
November 12, 2025
8 min read
Manufacturers with distributed facilities, legacy systems, and rigid labeling standards face complex printing and output challenges that affect productivity, raise risks, and drive up costs. Fortunately, scalable, secure solutions simplify print and output management across locations while reducing IT burden.
Print and Output Decision-Makers in Manufacturing
Within manufacturing environments, print and output management often spans multiple departments, which makes collaboration essential. IT administrators and enterprise resource planning (ERP) managers are two of the most influential stakeholders. IT teams focus on maintaining reliable infrastructure, ensuring printer uptime, managing network security, and minimizing system disruptions. ERP managers oversee the business and operational side by integrating data and managing workflows.
To achieve seamless, end-to-end output management, these two roles must work closely together. By doing so, they ensure print and output processes are unified, automated, and aligned with broader production goals. This partnership creates the foundation for greater efficiency, accuracy, and operational visibility across the entire manufacturing environment.
The Print Buyer: IT Administrators
Manufacturing IT administrators oversee, print environments that span multiple facilities, each with its own infrastructure, devices, and workflows. Admins must ensure uptime across all sites while keeping systems secure and accessible for users. They also need to minimize helpdesk tickets, reduce troubleshooting demands, and maintain service quality, all without expanding IT overhead.
The Output Buyer: ERP Managers
ERP managers view printing through the lens of operational continuity. One of their priorities is ensuring that output devices integrate seamlessly with ERP systems, particularly for label printing that drives production lines and order fulfillment. They need visibility into every stage of output workflows to quickly identify and fix issues before they halt operations. Even brief downtime can cause cascading delays across manufacturing and shipping, so ERP managers seek solutions that keep processes running smoothly and consistently.
Why Printing Is So Complex in Manufacturing
Manufacturers rely heavily on printing and labeling workflows to keep production and supply chains moving, but outdated infrastructures and complex environments create serious challenges. Many of these issues stem from legacy systems and fragmented processes that modern print management software can help solve.
1. Legacy Server-Based Infrastructure
Most manufacturing facilities still rely on traditional print servers, which have significant drawbacks. Aging servers require ongoing maintenance, patches, and hardware refreshes, which can drain IT budgets. Server failures can halt printing across entire facilities, leaving production idle. And scaling becomes a nightmare: each new location requires additional servers, IT resources, and setup, creating inefficiency at every stage.
2. High IT Burden
IT teams in manufacturing environments often spend disproportionate amounts of time dealing with print-related headaches. Maintaining and updating servers, troubleshooting connectivity issues, and manually setting up printers across sites eats into time that could be spent on higher-value projects. Helpdesk tickets pile up with requests for access, driver installations, and troubleshooting. Without modern print management solutions, print support becomes a constant drain on IT capacity.
3. Dispersed Sites
Manufacturers rarely operate from a single facility, and managing print infrastructure across dispersed sites introduces more complexity. Remote plants, warehouses, and specialized locations often lack on-site IT, making printer deployment or updates difficult. Remote procedures can be clunky, while in-person visits are costly and time-consuming. The result is an inconsistent user experience, with employees at different sites getting varying levels of access and functionality.
4. Security Vulnerabilities
Legacy print systems pose significant security risks to an industry already vulnerable to cyberattacks. Print servers are attractive entry points for attackers, and with limited visibility, IT teams often struggle to track who is printing what, when, and where. That lack of oversight makes it harder to meet compliance standards and increases the risk of unmonitored data leaks. Without proper controls, printing becomes a blind spot in the security strategy.
The Biggest Print Output Hurdles in Manufacturing
In manufacturing, printing is not just a back-office task; it is a critical part of keeping production lines moving and customer orders fulfilled. From barcode and shipping labels to compliance documentation, print output directly affects efficiency, accuracy, and revenue. Yet, the systems behind this seemingly simple process often create major bottlenecks. When print and output management break down, they can bring entire operations to a standstill. Two of the most persistent challenges are costly downtime and limited visibility.
1. Costly Downtime
Few industries feel the impact of downtime as intensely as manufacturing. When a print output system fails, it is not simply an IT problem but a production crisis. Label printing failures can prevent products from shipping, causing delays throughout the supply chain. On the factory floor, even short interruptions can force production lines to pause while teams troubleshoot printers or reprint labels. The financial effects are immediate: every minute of lost uptime results in wasted labor, delayed orders, and lost revenue.
Beyond the tangible costs, downtime can also damage customer confidence and disrupt carefully planned logistics. Building resilience into output systems is therefore a top operational priority for any manufacturer that wants to maintain reliability and meet demand.
2. Label Printing Visibility
Another major challenge is the lack of visibility into printing operations across multiple sites or facilities. Many manufacturers operate with fragmented systems, where each location runs its own printers and software with little centralized oversight. This creates significant blind spots. It becomes difficult to track what is being printed, where it is being printed, and how efficiently those resources are being used. Without clear data on print volumes or printer utilization, companies struggle to allocate resources effectively or identify underperforming equipment.
Quality control can also suffer when labeling errors go unnoticed until products have already shipped, leading to compliance risks or costly recalls. By gaining real-time visibility into label printing operations, manufacturers can improve accuracy, consistency, and efficiency, while also using data to make proactive decisions and prevent issues before they escalate.
Modernizing Manufacturing Print Systems With Vasion
Manufacturers need a modern approach to printing that eliminates outdated complexity, empowers end users, and strengthens security. Vasion Print delivers all three by replacing legacy systems with a scalable, cloud-based platform built for today’s distributed manufacturing environments.
Serverless Print Infrastructure
Vasion Print removes the burden of managing on-premises print servers, cutting costs and reducing IT overhead. With no servers to maintain, patch, or replace, teams avoid constant upkeep and minimize downtime risks. A unified, cloud-based platform provides consistent management across all sites, while effortless scaling allows new facilities to be added without additional infrastructure.
For example, one Vasion customer, KAEFER Australia, implemented Vasion Print and was able to make their print processes five times faster.
“It's a lot easier to deploy because we don't need to install a server at every site. It's also easier to make changes. We can delete printers, add printers, and deploy printers based on IP range,” said Liam Ping Tan, IT Team Lead at KAEFER Australia.
End User Empowerment
By simplifying the end user experience, Vasion Print reduces reliance on IT while giving employees more autonomy. An intuitive portal enables users to quickly find and install printers independently, while location-aware discovery automatically identifies nearby devices. One-click installation makes setup fast and seamless, eliminating the need for IT support.
“Anyone on our network can use the Vasion Print portal to find and install the closest printer to them, enabling them to install and print with a single click,” said Jaison Bailey, Senior Systems Engineer at CENTRIA.
Advanced Security
Security remains a top concern for manufacturers, and Vasion Print provides enterprise-grade safeguards without added complexity. Identity-based authentication ensures that users only print to authorized devices, while automated policy enforcement keeps printing aligned with organizational standards. Comprehensive auditing provides full visibility into print activity across all sites, strengthening compliance and reducing risk.
How Vasion Makes Output Management Seamless
Modern manufacturing environments depend on reliable, efficient printing to keep production lines moving and supply chains on track. Vasion Output adds another layer of intelligence to printing and labeling workflows, ensuring continuous operations and giving IT and ERP managers the visibility they need to prevent costly disruptions.
Intelligent Rules and Routing
To keep manufacturing operations running smoothly, automation must extend all the way to print management. Vasion’s output management software supports continuous production through intelligent rules and routing that eliminate manual intervention and minimize downtime. When a primary printer goes offline, the system automatically redirects print jobs to available devices, ensuring labels are produced without delay. This intelligent printer redirection keeps shipments moving and production lines operating without disruption.
Vasion Output also uses load balancing to distribute print jobs evenly across multiple printers. By preventing bottlenecks and avoiding overuse of specific devices, manufacturers can maintain consistent performance and extend the lifespan of their hardware. Combined with failover protection that activates backup printers instantly when an outage occurs, these automation features guarantee that printing continues seamlessly, even under pressure. The result is a resilient, self-adjusting print environment that supports nonstop manufacturing operations.
Centralized Output Console
Automation is only part of the equation. Equally important is having full visibility and control over the entire print environment. With Vasion Output’s centralized console, manufacturers gain a single, unified dashboard that brings every aspect of label printing into focus. From one place, teams can manage printers across all facilities, track print jobs in real time, and quickly address any errors or performance issues as they arise.
This centralized oversight provides a clear understanding of print activity across the organization. Real-time monitoring helps operations teams stay proactive, spotting issues before they escalate. Built-in performance analytics reveal trends, such as printer usage, error frequency, and output efficiency, empowering manufacturers to optimize their printing processes. With this level of insight and control, companies can make data-driven decisions that improve reliability, reduce costs, and maintain productivity across every stage of production.
Less Print Hassle, More Productivity With Vasion
By combining automation, centralized oversight, and user-friendly features, Vasion Print and Vasion Output give manufacturers the tools they need to reduce IT burden, strengthen security, and keep operations running smoothly.
Ready to simplify your manufacturing IT infrastructure and future-proof your print environment? Book a demo of Vasion Print and Vasion Output today.