>I think a really good way to avoid all of that is break the job up. Even if 80% are in the same major ZIP code, maybe you can break them up on ZIP+4. Or think about ZIP codes as a seperate issue and for the straight output task, just break them into n record/page jobs.

What I plan on doing so far is, have a form that allows them to enter a single zip code, a range of zip codes, or a specifice page number or page number range. Yes, they will have the ability to kill the printer by entering a zip range of 0 - 99999, or a similar page range, but, I don't want to force them to run the report a hundred times, (ya know, once for each zip code). I guess I can just put a message on the form warning them about printing huge reports.

My current calculations are:

10,000 pages

We have a few fast printers that average 30 ppm, so
Printer/Mins
1 333.3333333
2 166.6666667
3 111.1111111
4 83.33333333
5 66.66666667

I think 4 is a good number.