The solution was to use JasperReports. The business could design their templates in a iReport Designer, test with dummy data, put the jrxml templates in a dedicated storage, and a simple http call would merge the real data with the template in a java service (200 lines of code) resulting in a PDF. That PDF would then get printed using ColdFusion cfprint (those huge multi-source laser printers with 10 different drawers). It was worth spending £800 for CF just for the cfprint stuff.
Hundreds of these were printed and generated every day.