I was exactly in your same position 3 years ago. Here's the right way to think about it.
- cost savings: yes, please do it yourself. It will be more work at first, but eventually once you understand the technology and the process you can actually expand your production line because you control the production process and know its capabilities.
- process: you need to print, laminate, and cut. Keep those processes separate. Do not combine the machines, will be a nightmare. Those printer/cutter machines are for small batches.
- printer: stay with eco-solvent, skip on the UV printer. UV requires too much maintenance and has more moving parts. Eco-Solvent has been around forever and technology works. Brands I recommend Mimaki and Epson. make sure you get roll to roll. You will be printing entire rolls at a time.
- laminator: any of the major brands
- cutter: graphtec or summa. I use graphtec. Make sure you get the new ones with barcode readers.
- sizes: you will only need 54 inches. All rolls come in 54 inches. I have my setup for 64 inches and have never used anything 64 inches.
- outgassing: dont worry about it. I print with an Epson S40600 and outgassing has never been an issue. I go straight to cut, or laminate and cut. Most of the time the printed roll is just sitting around for a day or two. You do not have that much volume at all, your guys coming in part time can handle that.
My setup is Epson S40600, Royal Sovereign Laminator, and Graphtec Cutter. Been running this setup for 3 years. No problems. If I had to change anything would be the Epson printer for a Mimaki. My other Mimaki in the shop has been nothing but good to me (and I purchased used!!)