Print efficiency in Heatset Web Offset

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Print Efficiency in Heatset Web Offset


Print Efficiency in Heatset Web Offset


Status of Print Media

Increasing efficiency is crucial for printing business sustainability

Print end-users need to maintain cost efficiency in their print media spending

Burning topic for heat-set printers = How to maintain or reach positive profit margin in killing competition?

Efficiency development is very challenging for many printers

Equipment is no longer cost-competitive

Debt level prevents new investments and burdens cost level


Heatset printer – efficiency example

Heatset printing: Average paper use efficiency: 80% Average time efficiency: 65% Overall efficiency (80% x 65%) = 52%

Practical room for improvement is about 8% units in overall efficiency Overall efficiency (85% x 71%) = 60%

Printer with MEUR 70 turnover and 50 ktons paper usage About MEUR 1.5 lower paper costs

– (5% x 50k x 700€ - resale value) About MEUR 1.3 improved capacity utilisation margin

– (106% x gross margin) – same fixed costs)


Paper waste in heatset printing

StorageReel

preparationMakeready Running Bindery/trimming

~21%

“You cannot manage, what you cannot measure”

~0.5%

Wh

ite w

ate

~0

.5%

~2-10% ~3-6%

~1-

2%

~5-10%

Ext

ra c

opie

s

Trim

Co

re&

pa

cka

gin

g ~

1%


Time waste in heatset printing

• Example of time waste sources in heatset printing

• Percentages are strongly dependent on run lenghts


Paper waste categorisation

Trim waste (~5-10%) Trim waste is dependent on the layout design of the printed

produc t in question Trim waste optimisation requires

– Web width standardisation – to reduce stock items

– Product size standardisation – f ixed format offerings

– Effect ive cut-off ut ilisat ion

Storage waste (~0,5%) Paper storage losses due to damaged/lost reels Unused leftover reels



Core&Packaging (~1%) Core and packaging are included in the paper price

White waste (~0.5-1%) White waste consists of

– Slab waste (how much is taken from the reel)

– Core waste (how much is left on core on reel change)

Slab waste is more important Training of reel preparation personnel crucial

1250 mm reel diameter

50% of thepaper

10% of thepaper

Thickness, um Waste-%

5 layers 0.3 mm 0.1%

10 layers 0.6 mm 0.2 %

50 layers 3 mm 1 %

100 layers 6 mm 2%

Paper thickness 60 um



Makeready waste (~2-10%)

Makeready usually consists of– Colour ok

o Usually around 4000-6000 copies – however in some cases much more

o Can be influenced by good colour management and paper standardisation

– Folder adjustmentso Reel width and paper grade standardisation decreases

the time needed for folder adjustmentso Run sequences - similar jobs after each other



Running waste (~3-6%) Washing waste

– Depending on washing interval and amount of copies lost in wash

Other running waste– Including web breaks, folder jams and other unexpected

problems Can be decreased by paper grade standardisation known

behaviour of certain house papers

Extra sheets for bindery (1-2%) Amount of extra sheets printed on top of the actual order Should be calculated precisely in order to avoid extra waste


The effect of run length

Run length

“dependent” waste Makeready Extra copies

Run length

“independent” waste Washing Web breaks


Hypothetical case64-page magazine printed on

32-page press Run length 200 000 copies Web width 900 mm MWC 70 gsm Makeready 10 000/6 000 cps Washing interval 30 000 cps Extra sheets 1500 cps Average speed 35000 cps/h Press hourly rate 800€/h

Press cost: 12 733 € 31 %Paper cost: 24 963 € 62 %

Ink cost: 2 006 € 5 %Other cost 800 € 2 %

Printing cost 40 502 €

White waste 1,3 %Makeready waste 4,0 %

Washing waste 4,8 %Other running waste 1,0 %

Extra sheets 0,8 %11,8 %

Production waste without trim waste


Hypothetical case

64-page magazine printed on

32-page press Makeready 6000/4000 Washing interval 50 000 Extra sheets 800 Decrease slab waste 2mm

Decrease total cost 5%

Press cost: 11 842 € 31 %Paper cost: 24 051 € 62 %

Ink cost: 1 943 € 5 %Other cost 800 € 2 %

Printing cost 38 636 €

White waste 0,6 %Makeready waste 2,5 %

Washing waste 3,2 %Other running waste 1,0 %

Extra sheets 0,4 %7,7 %


Interested to hear more how Sappi can help increase efficiency from paper procurement to final product?

Please contact:[email protected]@sappi.com

Business

Print efficiency in Heatset Web Offset