In-plant Forum Spotlights Growth, AI and a Brand New Shop

For many years, In-plant Impressions has hosted an In-plant Forum during PRINTING United Expo, and the tradition continued on the first day of the 2026 show. Dozens of in-plant managers gathered for the session, giving them a welcome opportunity to mingle, network with peers, and compare notes on the equipment, technologies, and applications they were checking out on the show floor.

In-plant managers filled the room at the In-plant Forum.

IPI Editor Bob Neubauer kicked things off by sharing findings from the 2026 In-plant Capabilities, Performance, and Expansion research report. While the average in-plant employee count has slipped from 13 to 12 and annual operating budgets have declined nearly 8% to $2.93 million, more than half of survey respondents reported increases in both revenue and print volume in 2025.

Neubauer noted which services have expanded the most at in-plants over the past two years: flatbed printing, warehousing/fulfillment, and production inkjet printing. Among value-added services, photo printing, promotional products, and engraving have also expanded notably over the past two years.

In-plant managers filled the room at the In-plant Forum.

He also pointed out the applications that showed the greatest percentage growth at in-plants over the past two years: rigid signage, ADA-compliant signage, bills/statements, greeting cards, point-of-purchase displays, floor graphics, and stickers. Neubauer encouraged managers not yet offering these applications to take a closer look at them, noting that other in-plants are finding success with them.

Neubauer closed by offering examples of how in-plant managers are using AI to help manage their operations, analyze production data, enhance graphic design, and improve workflow. He also urged caution, reminding attendees never to enter proprietary data into open AI tools; to verify AI-generated information against trusted sources; and to require human review of anything shared externally. AI, he stressed, should be treated as an assistant not an authority — and used thoughtfully, since the data centers that power it consume substantial amounts of electricity and water.

“More and more customers are asking the printer, ‘How is AI touching our data?’ So you should think about it and – if you are using it – be ready to answer those questions,” he said.

Dave Earp talked about the new in-plant he started.

Then Dave Earp took the stage to share how he built a new in-plant from the ground up. The idea began when Melvin Management Co., parent company of Rural King, approached Earp about evaluating whether it made sense to bring more printing in-house. After 30 years at Lake Land College, where he had helped build a strong wide-format operation, Earp came aboard to determine what equipment and capabilities the new shop would need. Harvest Print & Media began in a facility (inside a mall, in a former shoe store) that required extensive work, including repairs to the walls, electrical system, lighting, and air conditioning.

“There was a lot of cost involved in a new startup,” Earp emphasized. “But it has been a very good journey. What I would say going forward is print’s not dead.”

Dave Earp spoke to a roomful of in-plant managers.

Earp then researched equipment based on the volume, speed, and variety of work the operation expected to handle. Because Rural King has 162 stores, the shop needed equipment capable of producing both cut-sheet work and large quantities of wide-format graphics. A visit to Konica Minolta led to Harvest Print & Media becoming the first U.S. facility to install the AccurioWide 320HS. Earp also added a Colex automated cutter, Roland TrueVis VG4-640, Duplo DC-618 slitter/cutter/creaser, AccurioPress C6100, and Shark paper cutter.

In-plant managers from Utah, Illinois, and California watch the presentations.

The eight-employee operation is now producing signage, displays, greeting cards, brochures, flyers, booklets, and other print for Rural King, along with work for outside customers. Most significantly, it has brought previously outsourced POP displays and store signage in-house, including department signs, restroom signs, greeting card displays, cash register graphics, and other signage used throughout Rural King stores.

"I'm really feeling good about print again," remarked Earp.

The conversation turned to workforce development and how Rural King is building the team needed to support that growth.

Drew Weckbach and Dave Earp

“We’ve been adding our capacity at the part-time level, growing those part-timers, and training them,” said Drew Weckbach, director of strategic initiatives from the Melvin Management Co. “Dave created a great learning and development culture, so we’re attracting great talent because of the culture.”

That effort extends beyond Rural King itself. Earp has worked to expose local students to print and its career opportunities, helping create a pipeline of potential employees.

“It’s been good,” he said. “We’ve got some graduates from the local university that come in and say this is actually kind of fun.”

For in-plant managers facing questions about whether it makes sense to keep printing in-house, Earp believes the best justification for an in-plant is that it lets the organization keep greater control over the printing process. Being able to serve as the organization’s primary print expert is key, particularly when working within a tight budget.