1. Print Efficiency in Heatset Web Offset
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2. Print Efficiency in Heatset Web Offset
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3. 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
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4. 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)
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5. Paper waste in heatset printing
Reel
Storage Makeready Running Bindery/trimming
preparation
~5-10%
Core&packaging ~1%
Extra copies
~0.5% ~2-10% ~3-6%
~1-2%
White wate ~0.5%
Trim
~21%
“You cannot manage, what you cannot measure”
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6. Time waste in heatset printing
• Example of time waste sources in heatset printing
• Percentages are strongly dependent on run lenghts
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7. Paper waste categorisation
 Trim waste (~5-10%)
 Trim waste is dependent on the layout design of the printed
product in question
 Trim waste optimisation requires
– Web width standardisation – to reduce stock items
– Product size standardisation – fixed format offerings
– Effective cut-off utilisation
 Storage waste (~0,5%)
 Paper storage losses due to damaged/lost reels
 Unused leftover reels
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8. Paper waste categorisation
 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 1250 mm reel diameter
10% of
 Training of reel preparation personnel crucial the
50% of the
paper
paper
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
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9. Paper waste categorisation
 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 adjustments
o Reel width and paper grade standardisation decreases
the time needed for folder adjustments
o Run sequences - similar jobs after each other
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10. Paper waste categorisation
 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
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11. The effect of run length
 Run length
“dependent” waste
 Makeready
 Extra copies
 Run length
“independent” waste
 Washing
 Web breaks
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12. Hypothetical case
Press cost: 12 733 € 31 %
64-page magazine printed on
Paper cost: 24 963 € 62 %
32-page press Ink cost: 2 006 € 5%
 Run length 200 000 copies Other cost 800 € 2%
 Web width 900 mm Printing cost 40 502 €
 MWC 70 gsm
 Makeready 10 000/6 000 cps White waste 1,3 %
 Washing interval 30 000 cps Makeready waste 4,0 %
 Extra sheets 1500 cps Washing waste 4,8 %
Other running waste 1,0 %
 Average speed 35000 cps/h
Extra sheets 0,8 %
 Press hourly rate 800€/h 11,8 %
Production waste without trim waste
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13. Hypothetical case
64-page magazine printed on Press cost: 11 842 € 31 %
32-page press Paper cost: 24 051 € 62 %
 Ink cost: 1 943 € 5%
Makeready 6000/4000
Other cost 800 € 2%
 Washing interval 50 000
Printing cost 38 636 €
 Extra sheets 800
 Decrease slab waste 2mm
White waste 0,6 %
Makeready waste 2,5 %
Washing waste 3,2 %
Decrease total cost 5% Other running waste 1,0 %
Extra sheets 0,4 %
7,7 %
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14. Interested to hear more how Sappi can help
increase efficiency from paper procurement to
final product?
Please contact:
Henrik.Damen@sappi.com
Jouni.Marttila@sappi.com
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