Calculate Flexo Press Savings Provided by a Servo Add On

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 a servo itpress press 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 a servo add on typically experiences substantially more material waste than a servo equipped press.

Bringing the flexo press into register in one press length is only one way that the servo add on 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 add on allows a flexo press to run the roll down to the core. In addition the servo 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 a servo add on 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?

Check out the expanded version of this discussion 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.



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