Printing Calculator
Calculate Flexo Press Savings Provided by the Servo 3000
Removing inefficiencies from flexo press operations can save on the cost of material waste and the cost of labor in adjusting, fixing, and re-doing print jobs. A flexo press has an overhead cost related to its operation and that overhead continues whether the press is running efficiently or not. Getting the most out of your flexo press will increase profits while overhead remains static.
What kind of press savings are we talking about?
A flexographic press equipped with the Servo 3000 add-on comes into register in one press length of material. This is the absolute minimum for any press. A standard flexo press not equipped with the re-register and servo infeed system offered by the Servo 3000 typically experiences substantially more material waste than a Servo 3000 equipped press.
Bringing the flexo press into register in one press length is only one way that the Servo 3000 saves money. Color “pull out” is a common occurrence as a press comes up to speed. With varying web tension the material will stretch or bunch up and colors will seem to wander about the web until the press reaches its speed and slowly regains registration. All of this can take substantially more than one press length! Every time a roll is changed, waste matrix removed, or a material splice moves through a standard press will need to restart and the same “pull out” issue occurs wasting substrate.
The excellent web tension maintained by the Servo 3000 allows a flexo press to run the roll down to the core. In addition the Servo 3000 saves in make ready time and material. This discussion only has to do with calculating press savings. It does not address the many other benefits of using the Servo 3000 to allow a press to print on a wider variety of substrates nor do such difficult jobs as printing or multi layer labels or finishing the same from a digital press.
What will you need to do to calculate savings?
An expanded version of this discussion can be found on the Rotary Technologies web site along with a savings calculator to make the job easy. The information and calculator are in both English and Spanish. You will enter your own company data into the calculator. Much of this you will know and some will require that you observe press operation and take measurements.
How much material is in the press from the first print unit?
To determine this with the press stopped, flag the roll at the production rewind and mark the web with a marker at the first print unit. Run the press until the mark is at the rewind. Remove the material by hand between the mark and the flag. Measure the material using a tape measure.
How much material is wasted to get the press into register after a restart?
To determine this with the press stopped, flag the roll at the product rewind. Run the press until it is back in register and flag the product rewind a second time. Remove the material between the flags by hand and measure with a tape measure.
Definitions and Formulas
Daily Savings
Daily footage saved = (Feet wasted to get press in register – material feet in press) x stops per shift x shifts per day
Cost of daily footage saved = cost per MSI x daily saved MSI
Daily save MSI = Daily footage saved x web width ÷ 1000
Time/Minutes Saved = Daily footage saved ÷ Average press speed
Overhead cost Saved = Press overhead ÷ 60 x Minutes saved
Summary Overview: Projections are based on a 20 day work month, 40 hours work shift. All time calculations are converted to hours.
With the Rotary Technologies Savings Calculator you will fill in the following information:
Cost Per MSI
Press Overhead/Hour
Web Width (Inches)
Average Press Speed FPM
Material in Press (Feet)
Material Used to Register (Feet)
Press Starts per Shift
Shifts per Day
You will receive daily savings data as follows:
Daily Material Savings
Feet
Cost
Daily Overhead Savings
Time/Minutes
Cost
You will receive expanded data for six, twelve, and eighteen months for the following:
Material Savings in Feet
Number of 5000′ Rolls Gained
Material Savings in Dollars
Number of Hours Saved
Number of Shifts Gained
Overhead Savings
Total Material + Overhead Savings
Check out the savings calculator at Rotary Technologies and learn how the Servo 3000 starts paying for itself the first day it is attached to your flexographic press.
About the Author
Jim Walker
Website: http://www.rotarytechnologies.com/
Jim Walker is a technical writer working for Rotary Technologies. With over two decades in the business of supporting flexo printers, Rotary Technologies offers the Servo 3000 Infeed + Re-register System, Series II, faster and more powerful than ever.
Please contact him at jim.walker@rotarytechnologies.com
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