The document discusses print efficiency in heatset web offset printing. It notes that increasing efficiency is crucial for sustainability in the printing business. On average, heatset printers currently achieve 80% paper use efficiency and 65% time efficiency, resulting in an overall efficiency of 52%. There is potential to improve overall efficiency to around 60% through measures like reducing paper waste, decreasing makeready times, and increasing press uptime. Specific examples are provided to illustrate how efficiency gains in areas like paper usage, press speeds, and waste reduction could significantly lower costs for printers.

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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