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[Getting Started - AI-Estimator] Step 3.2: Configure Your Products and Reference Data

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Written by Pradeep Sankaran

With your machines and substrates in place, it's time to configure the products you sell and how they're priced. This step covers two areas in Estimate Setup: Products (Categories, Field Rules, Conditional Steps) and Reference Data (the dropdown options, sizes, shipping, and packaging rules that drive the estimator interface).

As with machines and substrates, the recommended approach is to use the AI Configurator for most configuration. But in this article, we'll walk through the structure manually so you understand how everything fits together.

Your account already comes with a template that includes common product categories and reference data. Our recommendation: don't change it unless you need to. Remove what's irrelevant (e.g., delete large format categories if you only do commercial print), and edit the rest to match your operation rather than creating from scratch.


Part 1: Products

(Video) Walkthrough: Configuring Categories, Field Rules, and Conditional Steps

Categories

Categories are the broad product types you estimate — for example, PUR Books, Stitched Books, Leaflets & Flyers, Boards, Banners, and so on. You typically end up with 5 to 15 categories. All variations of a product type are contained within a single category.

For each category, you define:

  • Parts and Production Steps. A part is something that is independently produced and tracked. For example, a book has at least two parts: cover and inner. For each part, you build up a list of production steps (e.g., print, cut, crease, fold, laminate, spot finish). You can add or remove steps as needed — for example, always include polybagging, or exclude crease for digital jobs. Parts can be marked as optional (e.g., a cover on a self-covered book), and you can add as many parts as you need (dust jackets, inserts, etc.).

  • AI-Based Step Conditions. You can write plain-English conditions to dynamically add or remove steps. For example: "If paper weight for inner is less than 170 GSM, remove crease step." The system applies these conditions automatically during estimation.

  • Category Type. Determines how the product is imposed — for example, bound (signatures), flat (single sheet), folded (panels), die-cut, and so on. The template already has the correct type for each category.

  • Price Adjustment Model. Choose how you express your pricing:

    • Gross Profit % (GP%): Markup as a percentage of selling price. Formula: Total Markups ÷ Total Estimate.

    • Value-Added % (VA%): Machine and labor cost as a percentage of total. Formula: (Labor + Machine) ÷ Total Estimate.

    • VA per Press Hour: Value added per hour of press time. Formula: (Labor + Machine) ÷ Total Press Time (hours).

    You can use different models for different categories — for example, VA% for commercial print and GP% for large format.

  • Default Markups. For each category, define default markups across seven cost buckets: Substrate, Material, Other Material, Labor, Machine, Delivery, and Outwork. These markups are your starting point — pricing rules (covered in Step 3.3) can adjust them for specific conditions.

  • Other Settings. Categories also include options like mix production (allow different machines/sheet sizes per part), allow same-size sheet (economy/no-bleed printing), ink coverage tiers, bleed settings, and product-specific parameters (e.g., tile overlap for large format, hinge gap for hardcover books). Use the tooltips for guidance on each.

Field Rules

Field Rules control the dropdown logic for three specific fields: lamination, lamination coverage, and materials (for large format). They define which options appear in each dropdown based on the category and the user's selections. For example: when lamination is set to "Gloss," show coverage options "Both Sides" and "Cover Only"; when set to "None," show only "N/A."

The template already has field rules configured. You'll typically only need to edit these when adding new lamination options or new large format materials.

Conditional Steps

Conditional Steps are additional finishing operations that can be added while creating an estimate — on top of the core production steps defined in the category. Examples include polybagging, shrink wrapping, coating, and other add-on operations.

The items in this list come from your price models (under Finishing Machines and Binding Machines). You don't create them here — they appear automatically based on what you've configured.

For each conditional step, you control:

  • Show by Default — If enabled, the step appears above the fold in the estimate interface (always visible). If disabled, it's hidden under "Additional Options."

  • Enable for specific parts — Show the step inline within a specific part (e.g., show polybagging in the inner section, or in the cover section).


Part 2: Reference Data

(Video) Walkthrough: Configuring Reference Data for Products

Reference Data controls the dropdown options, sizes, page rules, and shipping configuration that appear in the estimator interface. Each table defines what options your estimators see when creating estimates for each product category.

Finish Sizes

Pre-defined finish sizes (e.g., A4, Letter, A3) with their dimensions, assigned to specific categories. When a size is enabled for a category, it appears in the size dropdown. If no pre-defined sizes are enabled, only "Custom Size" appears, allowing estimators to enter any dimensions. For packaging categories, sizes include three dimensions (width, height, length).

Page Limits

Minimum, maximum, and increment rules for page counts per category and part. For example, a stitched book inner might allow 4 to 96 pages in increments of 4. The AI uses these limits too — if a customer requests 100 pages in a stitched book, the AI will suggest switching to a PUR book instead.

Page Folds

For folded product categories, this defines the available fold types with panel layouts — how many panels wide and high, and how many pages each fold type represents after folding.

Page Colors

Pre-defined color options (e.g., "Full colour / both sides," "Black only / both sides") with front and back color channel counts (4 = full color CMYK, 1 = black only), assigned to categories. You can also include a "no printing" option (0/0) for parts that shouldn't be printed.

Die Cut Templates

For categories with the die-cut type, this defines 2D die-cut templates (e.g., pocket folders) with fold counts, extra dimensions, and minimum size guardrails. These templates translate the finished size to the flat size for correct imposition.

Packaging Configuration

3D die-cut templates for packaging categories (e.g., ECMA, Fefco styles). Each template defines how the packaging dimensions translate to the flat sheet for production. The most popular templates are included in your account template.

Packaging Die Library

If you have existing dies in storage, register them here with their style and dimensions. When the AI detects a match during estimation, it will flag that a die is already available — reducing production cost.

Shipping Packages

Define your shipping boxes, tubes, and pallets with dimensions, weight capacity, material cost, and labor cost. Assign which product categories each package type can hold. The system automatically optimizes — packing products into boxes, then palletizing when it's cheaper to ship on a pallet than as individual boxes.

Shipping Methods

For each package type, define the available delivery methods, destinations, delivery times, and shipping costs. Supports tiered pricing (e.g., first box costs $15.50, additional boxes cost $8 each). Set one method as "Default" per package type — this is what the estimator uses automatically unless manually changed.

Spot Finishing (Legacy)

Define pricing for spot finishes (Spot UV, Soft Touch, etc.) per sheet size, with optional film charges and carriage/delivery fees for outwork. Assign to specific categories.

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