We work in the printing industry.
Years ago we designed an application in Visual Basic to print on the play slip.
Keeping the preprinted form registered was an issue, but if you keep the picker roller absolutely clean, there are few problems with registration.
The picker roller is the one that first grabs the paper stock and feed in to the printing device.
If it's not clean, it can miscue the input sensor and cause the paper to feed in skewed.
Cleaning it can be done with 90% Isopropyl Alcohol and a lint free cloth.
Bad or flat spots can develop on the picker roll and cause miscues as well; in that case, you'll need to replace the picker roll.
Also, there may be a separator roller or pad underneath the picker roller; that too may need to be cleaned or replaced.
As far as ink, some scanners are sensitive to certain wavelengths of light and can only be use with specific kinds of inks.
The reflected colors or absorbed colors determine if the scanner is capable of reading the play slip.
Typically, there is a four color process that uses Cyan, Magenta, Yellow and Black to make the image on the sheet.
The majority of the time, Black is used as the timing marks because it can be sensed by most scanners.
However, some times the Cyan can be picked up by a scanner and cause a false reading.
Also, the four color process means that some areas of the print have Black in the print and can cause a flase reading.
In those cases, an ICC Profile can be used to strip out the Black in specific areas of print to ensure there is no Black to cause a false reading.
In addition, some Black inks might not be scannable due to the fact they don't reflect or absorb the proper wavelength of light.
As this relates to Volume, you home printer may work for a few hundred well, but if you're really ambitious, you might need an industrial printer.
The following are the kind of industrial printer we work on.
These would most definitely run through all possible combinations in vastly less time.
We've also work on everything from table top models, mid range cut sheet/continuous feed and continuous feed industrial toner.