Print efficiency in Heatset Web Offset

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Print efficiency in Heatset Web Offset

  1. 1. Print Efficiency in Heatset Web Offset1 | [Presentation title] | [Client Name] | [Date]
  2. 2. Print Efficiency in Heatset Web Offset2 | [Presentation title] | [Client Name] | [Date]
  3. 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 level3 | [Presentation title] | [Client Name] | [Date]
  4. 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)4 | [Presentation title] | [Client Name] | [Date]
  5. 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”5 | [Presentation title] | [Client Name] | [Date]
  6. 6. Time waste in heatset printing • Example of time waste sources in heatset printing • Percentages are strongly dependent on run lenghts6 | [Presentation title] | [Client Name] | [Date]
  7. 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 reels7 | [Presentation title] | [Client Name] | [Date]
  8. 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 um8 | [Presentation title] | [Client Name] | [Date]
  9. 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 other9 | [Presentation title] | [Client Name] | [Date]
  10. 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 waste10 | [Presentation title] | [Client Name] | [Date]
  11. 11. The effect of run length  Run length “dependent” waste  Makeready  Extra copies  Run length “independent” waste  Washing  Web breaks11 | [Presentation title] | [Client Name] | [Date]
  12. 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 waste12 | [Presentation title] | [Client Name] | [Date]
  13. 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 %13 | [Presentation title] | [Client Name] | [Date]
  14. 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.com14 | [Presentation title] | [Client Name] | [Date]

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