COST-EFFECTIVE SUBSTRATE MANAGEMENT FOR PRINTERS

Transcription

1 GG107 GUIDE COST-EFFECTIVE SUBSTRATE MANAGEMENT FOR PRINTERS GOOD PRACTICE: Proven technology and techniques for profitable environmental improvement

2 COST-EFFECTIVE SUBSTRATE MANAGEMENT FOR PRINTERS This Good Practice Guide was produced by the Environmental Technology Best Practice Programme Prepared with assistance from: Entec UK Ltd Crown copyright. First printed December This material may be freely reproduced except for sale or advertising purposes. Printed on paper containing 75% post-consumer waste.

3 SUMMARY In the printing process, the substrate (paper, board, polythene, PVC, polycarbonate, fabric, etc) can represent between 80-90% of the raw material costs for any printed product. It is estimated that the average loss of substrate through the printing process is 6%, within a range of 2-25% depending on the complexity of the job and the stage in the process. For paper and board alone this is equivalent to as much as tonnes/year. For a medium-sized printing company this can be equivalent to a loss in the region of /year. The technical challenge for any printer is to reduce substrate spoilage and wastage to a minimum to reduce production costs while maintaining printing speed, output and quality. This Good Practice Guide focuses on identifying the true cost of substrate waste, and preventing and reducing the loss of substrate during the printing operation. It shows how reducing wastage and fully utilising substrate throughout the process can generate cost savings in other areas. This Guide: demonstrates a method of calculating the quantity of substrate lost; identifies the changing value of the substrate as it progresses through the printing process; provides practical measures to reduce substrate losses; identifies methods of reducing avoidable losses. Many of the measures identified can be put into practice immediately. An Action Plan is included at the back of this Guide to help you get started.

4 CONTENTS Section Page 1 Introduction Why reduce substrate losses? 1 2 Quantifying your losses How to calculate losses Getting started 5 3 Reducing waste in your process Estimating and ordering Handling and storage Set-up/make-ready Press run Trimming and binding Counting and delivery Other areas 16 4 New technology Press design Colour matching/computerised set-up/print monitoring Ink system Dampening systems Advanced mechanical handling equipment Static electricity reduction 19 5 Action plan 20 Appendix Sample worksheets 21

5

6 1 INTRODUCTION This Good Practice Guide aims to help your company save money and improve its environmental performance by providing practical advice on how to reduce production costs while maintaining printing speed, output and quality. By focusing on preventing and reducing the loss of substrates (paper, board, polythene, PVC, polycarbonate, fabric, etc) during the printing process, the Guide explains how to minimise the use of materials, energy and time. It demonstrates that by reducing waste and fully utilising substrate throughout the process, cost savings in other areas can be achieved. 1 The printing industry is very diverse and the Guide highlights reduction methods which can be used throughout the printing industry regardless of: substrates used; printing methods employed; products manufactured; types of inks used. However, each company s printing operation is geared to its own particular business and products. Therefore, for optimum cost savings, companies should use the Sections of this Guide which best fit their operation. 1.1 WHY REDUCE SUBSTRATE LOSSES? It is estimated that the average loss of substrate through the printing process is 6%, within a range of 2-25% depending on the complexity of the job and the stage in the process. Assuming the average losses were all virgin substrate, this is equivalent to losses of 175 million/year across the industry. This Guide shows that the total cost of waste can be significantly more than the value of the wasted substrate. For a medium-sized printing company this is equivalent to a loss in the region of /year. Prevention and reduction of substrate loss will help save money - savings which go straight to the bottom line. Due to the nature of the printing industry, where the customers have specific requirements, a proportion of wastage is unavoidable. The aim should be to reduce wastage to a minimum. This Guide, therefore: demonstrates a method of calculating the quantity of substrate lost; identifies the changing value of the substrate as it progresses through the printing process; provides practical measures to eliminate unnecessary substrate losses; identifies methods of reducing avoidable losses; highlights potential savings in other areas as a result of reducing substrate loss. This Guide starts by quantifying the losses within the printing process and identifying the true cost of wasted substrate. It then examines the printing process, looks at the various stages of the process in turn, considers how and why materials are lost, and identifies potential methods for reducing the losses. This Guide illustrates how the value of the substrate increases as it moves through the printing process. 1

7 2 QUANTIFYING YOUR LOSSES The aim of managing the use of substrate is to ensure that your company obtains the full value from the materials purchased. It is not possible to manage your substrate if you do not evaluate exactly how it is used in the process. Therefore, the first step towards good management is knowing how much substrate is used in your printing process. 2 To understand what causes substrate loss, it is important to quantify the amount of substrate used on any job, identify which stages of the process produce the greatest losses and highlight what causes the losses. For example, common factors affecting substrate loss are: type of substrate; a particular press; ink problems; inaccurate estimating; poor checking; damaged stock; complexity of the job; old machinery; breakdowns. A simplified printing operation is shown in Fig 1. Fig 1 The printing process 2

8 To quantify the value of the substrate through the printing process, the value of the other raw materials, press time and staff time should also be considered. Substrate, ink, etc (raw materials). When raw materials are wasted and disposed of, the cost of such wastage is not just the disposal cost but also the purchase price of the raw materials. Press time. Running a press has a number of associated costs, eg energy and maintenance. Therefore any errors on a print run, which result in substrate losses, have a cost because press time has been used without converting raw materials to finished products. This means that the press has not been fully utilised and the time lost could have been used to print other jobs. Staff time. Staff time is often an overlooked cost. The staff time spent estimating, ordering, storing, preparing plates and screens, and setting up presses contributes to the cost of a job and the true value of wasted materials HOW TO CALCULATE LOSSES The most accurate method of determining the true cost of waste is to calculate the cost of substrate losses on a job-by-job basis. By looking at the costs on this basis, you can calculate the losses for: all jobs; a number of different types of job; an individual job which is representative of normal press runs. This Guide demonstrates two methods of quantifying the costs and losses within the printing process - an overview method and a cost at each stage approach Overview This method uses figures that are likely to be available within your company, or are easily estimated, without the need for additional weighing or counting. It can give an overall assessment of the wastage on a job by a desktop calculation. The total quantities and costs of materials and effort used to produce the finished product are considered and the costs are compared against the quantity of substrate issued to the job and the actual quantity dispatched to the customer. The example Worksheet 1 (Fig 2) breaks down the process inputs and allows the calculation of: the true cost of a job; the unit value of the finished product; the cost of wastage. A blank worksheet which can be photocopied has been included in the Appendix. Having determined and recorded the cost of the losses, the information in this Guide can be used to identify methods of reducing wastage. Following the introduction of waste reduction methods, Worksheet 1 can be filled in again to monitor performance Costs at each stage This method provides a more accurate breakdown of the wastage within your company, but is likely to require additional effort to calculate precisely the losses. The material lost at each stage needs to be quantified by weighing or counting the spoilage. Breaking down the costs and losses at each stage of the process allows the most costly or wasteful areas of the process to be identified, thus enabling these areas to be addressed first for maximum benefit. 3

9 JOB SUMMARY Job description Press used Type of substrate No. of colours High quality store bags Press No. 3 Polyethylene 3 PRODUCT DETAILS Print run Quantity printed Quantity dispatched Quantity of overruns/overs bags SUBSTRATE DETAILS Substrate quantity issued Substrate quantity Substrate quantity in Substrate quantity* for job* in all finished product dispatched* in overruns/overs** product* kg 840 kg 800 kg 40 kg COST SUMMARY Total quantity Unit value Total cost or measure ( /quantity) ( ) (kg, hours, etc) Substrate ordered or issued for the job kg x 1.25/kg = Other materials issued (ink, solvent, plates, etc) 140 kg ink x 4.50/kg = 630 Press time (the cost of running the press for a set period of time) 10 hours x 60/hour = 600 Staff time: estimating and ordering 7 hours x 50 = 350 trimming and binding 10 hours x 30 = 300 counting and delivery 3 hours x 30 = 90 TOTAL COST OF JOB Unit value of = Total cost of job = = 3.04/(sheet, m, kg) finished product Substrate quantity issued for job kg Cost of substrate = (quantity of substrate issued for job quantity dispatched) x unit value losses = ( ) x 3.04 = 912 * Usually a weight (kg) determined by weighing/calculating substrate and product, but other consistent measures can be used (eg sheets, metres, rolls). ** This can be used to assess substrate used in overruns/overs (extra items above the agreed total ordered) and monitor excessive production. Count as waste any which the customer does not receive. Fig 2 Worksheet 1 - calculating costs and wastage by job 4

10 The Tables provided in Section 3 can be used to help identify the costs of individual stages in the process and the quantity of substrate lost during each stage. Completing these Tables for a job you select will demonstrate how the value of the substrate increases through the printing process and will allow you to determine the cost of lost substrate. The steps involved in calculating the unit cost of the substrate and the cost of waste at each stage are detailed in Section 3. In summary: Total cost of all previous processing activities Quantity of good substrate left after each process stage = Unit cost of substrate after each process stage ( /kg or other unit) (A) A x Quantity of substrate lost during process stage = Cost of waste after each process stage The total cost of substrate losses can be determined by adding up the cost of waste from each stage. This figure will reflect the increased value of the substrate as a result of the printing process and not just the original value of the substrate. Fig 3 is an example developed using the information in Section 3. A blank worksheet which can be photocopied has been included in the Appendix GETTING STARTED The extent to which you examine the losses will depend on the time and resources available to your company. The following are methods of integrating such assessments into your working practices. Add the quantity of substrate lost and the time spent in each area to the job card, to allow an assessment of each job to be made. Carry out an assessment on a single job to identify the key areas of wastage (quantity and cost), implement an appropriate waste reduction method and carry out another similar print run to determine the level of improvement. Carry out an overview on all jobs, but select a small number of jobs and look at each stage of the process. It can be beneficial to give someone within your company responsibility for waste reduction, to co-ordinate the assessment of material losses and to initiate and implement waste reduction programmes. A co-ordinator needs: direct access to senior management and its support; enthusiasm and the ability to motivate people; a working knowledge of the company s processes or a willingness to learn them. The main responsibilities of a co-ordinator can include: collecting and collating information to quantify losses; selecting priority action areas; identifying waste prevention ideas (in conjunction with process operators); setting up a waste reduction team(s); raising awareness of waste reduction within the workplace; initiating monitoring systems to provide feedback on the company s waste reduction performance to both management and the workforce. 5

11 Job: Print A4 leaflets on 80 gsm white (600 kg purchased for job). Estimating (time) Ordering (time) Handling and storage Substrate Totals Cost ( ) Quantity lost n/a n/a 18 kg n/a 18 kg Quantity left after stage = Quantity ordered Quantity lost = = 582 kg Total cost Unit cost of substrate after storage = = Quantity left after stage 582 kg = 2.06/kg Cost of waste after storage = Unit cost x quantity = 2.06 x 18 kg = Table 1 Value of substrate after estimating, ordering, handling and storage Totals after estimating, ordering, etc Set-up (time and materials) Totals Totals after set-up Press run (press time/downtime) Totals Cost Quantity ( ) lost kg kg kg Table 2 Value of substrate after set-up/make-ready Cost ( ) Quantity lost kg kg kg Table 3 Value of substrate after press run Unit cost of substrate after set-up = 2200 = 3.93/kg 560 kg Cost of waste after set-up = 3.93 x 22 kg = Unit cost of substrate after press run = = 8.35/kg 527 kg Cost of waste after press run = 8.35 x 33 kg = Unit cost of substrate = = 9.63/kg after trimming etc. 509 kg Cost of waste after trimming etc. = Totals after press run Trimming and binding (time and overheads) Totals Cost ( ) Quantity lost kg kg kg Table 4 Value of substrate after trimming and binding Unit cost of substrate after delivery = = 10.85/kg 507 kg Cost of waste after delivery = x 2 kg = Totals after trimming and binding Counting and delivery (time, materials and transport) Totals Cost ( ) Quantity lost kg kg kg Table 5 Value of substrate after counting and delivery % of sheets lost = (93 kg/600 kg) x 100 =15.5% Therefore value of substrate lost = ( / 600) x 100 = 99% as a percentage of the original cost of substrate Cost of waste = Fig 3 A worked example of calculating costs at each stage of the printing process (using Sections 3.1 to 3.6) 6

12 3 REDUCING WASTE IN YOUR PROCESS The printing process has a number of distinct stages which combine to produce the finished product. Each stage can, for different reasons, result in the loss of substrate. This Section looks at each stage to identify potential areas of wastage and options for minimising the level of material lost. The stages considered are outlined in Fig 4. 3 Fig 4 Typical waste flows in a printing operation 7

13 3.1 ESTIMATING AND ORDERING Estimating and ordering materials is a key stage in the printing process. Accuracy in these areas can often make the difference between profit, break-even or loss on a job. Typical wastes Over-estimation on jobs. Over-ordering of stock. Over-allowance for wastage. Wrong-sized reels/sheets ordered, thus creating excessive trim. How to locate/quantify waste Set up a system to record any estimating/ordering problems, eg create a standard form. Record how much excess material was ordered compared with that used/printed on Value of substrate 3 At this stage in the process no substrate has been delivered to your company and therefore none has yet been lost. However, it is important to determine the intended utilisation of the substrate, that is the percentage of the substrate that will end up as the product, and from this produce a job summary. % utilisation = Area printed on x 100 =...% Area of substrate The closer this value is to 100%, the more effective the use of the substrate and therefore a more efficient use of raw materials Wastebusting ideas To reduce changeovers and stock requirements, companies often keep a limited range of web widths. Review carefully whether these are the most appropriate for the range of cut sizes required. You may be able to reduce the amount of trim. Alternatively, order for a specific job - this includes sheet size and reel length. For example, if a print run needs m of paper, it may be better to order four m reels rather than five standard m reels; this not only reduces waste, but also reduces changeover time. Carrying high levels of stock also increases the risk of damage during handling and storage. When ordering, specify metal reel cores, instead of cardboard, because these can reduce the amount of damage to reels. In addition, metal cores are easier to re-use and can be returned to the supplier. Consider doubling up jobs by printing two different jobs on one sheet to utilise the greatest area possible on the sheet. Fig 5 shows a complex job (A) being printed with a simple job (B). However, this may not always be possible and depends on the shape and colours involved. Review estimation methods. Always make sure that your estimating procedure has a feedback loop which enables you to compare estimate with actual. Over-estimation causes waste, while under-estimation causes shortages. Without feedback, overs allowances tend to increase. 8

14 B B A 3 Fig 5 Printing two different jobs on one sheet 3.2 HANDLING AND STORAGE Handling and storage of substrate prior to the printing process can result in a large amount of avoidable waste. This can, in general, be minimised by good housekeeping and staff awareness. Typical wastes Damaged reels/sheets from supplier. Tears, cuts or nicks in reel edges/corners during storage. Tears/cut from forklift prongs. Crushed cores. Dust build-up. How to locate/quantify waste Set up a system to monitor incoming goods and record any damage that is identified. If damage occurs during storage/transport, record when/how the damage happened - this will highlight areas of greatest risk. Record how much stock is damaged (weight or number of sheets) Value of substrate The value of the substrate at this stage of the process can be calculated by using the following table (generic values are given below). Estimating (time) Ordering (time) Handling and storage Substrate Totals Cost ( ) Quantity lost Generic substrate values after handling and storage Table 1 Value of substrate after estimating, ordering, handling and storage Sheet paper Paper roll Film roll and board 0.75/kg 2.50/kg 0.73/kg 9

15 3.2.2 Wastebusting ideas Paper reels/sheets are vulnerable to damage. For example, the circumference of a reel is greatest at the surface of the reel, therefore damage here has a significant effect. A tear/cut penetrating 5% into the surface of a paper reel damages 10% of the paper. On delivery of materials: Check the quality of incoming substrate and return to the supplier if damaged. If impaired materials are not identified upon delivery, the job will bear the cost of the damage. Make sure the substrate meets the ordered specifications - correct size, gauge and quantity. Send back if incorrect or if the problem cannot be rectified. Making do with the wrong size can create additional wastes. Ensure you receive what you ordered. During storage: 3 Store pallets and reels singly rather than stacked on top of one other. This reduces the risk of damage when substrate is moved in and out of storage. If storage space is limited then shelving can be used to prevent materials being double stacked. To reduce the possibility of damage, keep reel ends covered and wrapping on substrate until press set-up. Where possible, rewrap reels between print runs. Wrapping also keeps dust off materials during storage; this is significant because dust can cause problems on the presses, in particular in flexographic printing. A newspaper printing company has reduced substrate damage to reels by keeping the cardboard wrapping and plastic ends on the reels until they are ready for loading onto the presses. Excessive changes in humidity can cause dimensional changes and distortion in paper and board. Therefore, ensure that the storage conditions will not cause deterioration in the quality of the substrate. Movement of materials around the factory can result in damage to substrate. To avoid such damage: Take care when transporting sheets and reels with a forklift because the forks can easily cut or tear the paper or film. Ensure that reels are properly secured during transport. Avoid using broken pallets otherwise the substrate may fall. Handle reels by the core with special lifting gear - this can avoid damage caused by manual handling. Provide regular training for forklift drivers and ensure that staff are aware of the costs of wastage caused by careless handling. Redesign the storage area layout if there is not enough room to allow forklifts to turn without damaging the substrate. Protect the ends of reels or the top and bottom of sheet piles by resting reels and sheets on waste card or make-ready waste, rather than directly on pallets. Reshape damaged cores using a specially designed machine. A sheet-fed lithographic printer separates and collects damaged sheets in a variety of sizes. The damaged areas are then trimmed off and the sheets re-used for print runs/make-ready. This is calculated to achieve annual savings of in raw materials. 10

16 3.3 SET-UP/MAKE-READY Large quantities of substrate can be lost when the press is being prepared for printing, ie as the rollers and plates are aligned and the ink profile and flows are adjusted. For the majority of companies, set-up/make-ready is the stage in the printing process that accounts for the greatest material losses. Trends towards shorter press runs make this an even more important issue. Typical wastes Lines, blotches, etc. Tears. Colour/pattern changes. How to locate/quantify waste Set up a special bin at the side of each press to collect spoilage. Analyse the loss from the job (weight or number of sheets). Record the reasons for losses Value of substrate The value of the substrate at this stage of the process can be calculated by using the following table (generic values are given below). Totals after estimating, ordering, etc Set-up (time and materials) Totals Cost ( ) Quantity lost Table 2 Value of substrate after set-up/make-ready Generic substrate values after set-up/make-ready Sheet paper Paper roll Film roll and board 0.95/kg 2.70/kg 0.88/kg Wastebusting ideas A certain amount of waste at this stage is unavoidable. However, the following points should help to reduce the amount created. Ensure your customers requirements have been interpreted correctly to prevent wastage occurring. Customer requirements can be checked by using bromide or ink-jet proofs, job mock-ups and order acknowledgements. These methods of checking customer requirements can also be carried out at the estimating stage. Check the print quality by comparing printed sheets with proofs, perhaps using a viewing booth (see Section 4.2.3), before continuing with a print run. Agree print colour with the customer before running a whole job to ensure that the colour matches their specifications. This will also reduce the number of returns. A variety of technological devices can reduce start-up wastage, eg a pre-set scanner machine automatically sets the ink for the print presses thus reducing set-up time, ink and paper waste. The computer is able to use information from previous jobs where set-up was done well, and can copy the relevant information. This is especially useful for repeat jobs. Efficient job planning can reduce the need for press set-up, eg keep one press running on repeat orders or if printing one-two across a reel, try and make the next job follow a similar pattern. Sheet fed The material used for the initial press set-up/make-ready does not have to be high quality sheets. It can be lower quality material from the paper supplier or spoiled sheets from previous press runs. However, material used for set-up should be similar to the material for 11

17 the job in question, because differences in thickness, absorption capacity and size can result in the press needing additional setting when the virgin material is used. Spoiled sheets can be used as many as six times for setting up. At a card printing company, running waste is put to good use as make-ready where it is incorporated into a setter which consists of sheets of card. This is made up of a combination of 50 sheets of running waste, then 5 sheets of virgin material followed by another 50 sheets of running waste and so on. The virgin sheets are used so that the press operator can see whether the press is ready for a print run. A small amount of virgin material is used as a final check. This is estimated to have reduced make-ready material by 50%. Running waste can be used only once because it is printed on both sides and would deposit excess material on the print rollers and necessitate extra cleaning if used again. Raw material savings of approximately /year have been achieved. 3 Web fed When preparing paper rolls for loading onto the press, ensure that the minimum depth of paper is cut away or slabbed off to provide a clean/undamaged leading edge. A specially designed knife with a built-in reel protector can minimise slabbing loss. Remember, careful handling of paper rolls can minimise damage and thus reduce slabbing off. Set up on sub-standard film - you could ask for such reels from the supplier. When ordering for a specific job you could also request sub-standard reels to be included so that these can be used for set-up/make-ready. Set up using the same gauge film as for the print run because different gauge film will require additional setting up when print film is put on the presses. 3.4 PRESS RUN Running the press is the most critical part of the printing process. With presses running at over 200 sheets or 200 metres/minute, any changes in colour, alignment or temperature/humidity can quickly result in large quantities of substrate loss. Therefore, the ability to identify printing errors rapidly is very important when attempting to minimise substrate losses. Substrate losses almost always result in press stoppages and downtime, thus time-saving is an important factor in this Section. Typical wastes Web breaks. Colour/pattern changes. Hickeys. Changeover of reels/sheets. How to locate/quantify waste Set up a special bin and collect spoilage. Record losses (weight or number of sheets). Record and analyse reasons for losses. Consider computer analysis Value of substrate The value of the substrate at this stage of the process can be calculated by using the following table (generic values are given below). Generic substrate values after press run Totals after set-up Press run (press time/downtime) Cost ( ) Quantity lost 12 Totals Table 3 Value of substrate after press run Sheet paper Paper roll Film roll and board 1.25/kg 3.70/kg 1.13/kg

18 3.4.2 Wastebusting ideas Monitoring colour and ink density during printing, either operator-based or using a specialised computer system, can reduce the possibility of errors and ensures that any errors are detected quickly, thus reducing waste. Training staff to operate the presses correctly can reduce wastage because they are then able to correct errors without delay. Training carried out by press manufacturers is often the most cost-effective because of their knowledge and experience of their equipment. Certain substrates are sensitive to changes in temperature and humidity and can expand or contract under different conditions. This can result in misalignment of the image. Therefore, it is important to be aware if your substrate is affected by environmental factors and ensure that the printing of such substrate is carried out in the correct conditions. Sheet and web fed Using the largest possible print rolls can minimise changeover time and waste. This may mean that mechanical handling is required. However, this in turn can reduce the risk of damage to reels. Reel changes create waste. To minimise stoppage time a part reel as well as an exhausted reel could be replaced at the same time. Standardising reel lengths means that all parts are changed together, thus minimising stoppages and waste. Use of automatic changeover systems wastes less material than stopping for a manual splice. There are two main types - a dead-stop system and a flying splice. For paper rolls, when cutting away errors from the print run ensure that the minimum depth/length of paper is slabbed off. Excess slabbing off creates waste. A specially designed slabbing knife with a built-in reel protector can minimise slabbing loss. Improving the specification of the paper used can reduce the number of web-breaks and hence reduce the need for stoppages and material losses. Changes in specification can be introduced only after consultation with suppliers and customers. Changes in specification should be closely monitored to ensure that the higher specification material is performing as expected. Using larger cores (150 mm rather than 75 mm) can reduce creasing at the core. This means that reels can be run nearer to the core when printing and so the maximum amount of material is used. Introducing new monitoring technology may reduce substrate waste because it can reduce the time taken to identify faults. 3 A web printing company introduced two fault-tracking machines. Each machine has a camera positioned on the press which records the printed image and compares it to the correct image stored in the memory. If a fault is detected, the press operator is then alerted and can respond instantly. The problem is then resolved and a mark placed on the reel showing the position of the fault. The response time is considerably reduced because previously this was done manually by an operator scanning a screen showing the printed image. Problems can be solved within about m, however with the old system it could take up to m/fault. The two machines had a capital cost of and have produced annual savings of

19 3.5 TRIMMING AND BINDING Trimming and binding will always produce waste substrate. Waste from trimming the edge of webs and sheets can be caused by poor estimating, customer requirements, product design and press specification. It is important that excess amounts of such wastes are identified and the estimators informed. Waste substrate also occurs as a result of poor handling and operation of cutting and binding equipment, and it is these wastes which should be examined. Trimming and binding waste costs the same as other substrate wastes. Typical wastes Excessive trim waste. Trimming off errors. Slabbing off too much. How to locate/quantify waste Set up a special bin and collect trim waste for each job. Record amount of wastage (weight or number of sheets). Record reasons for trim wastes, eg wastage due to cutting errors or poor utilisation of substrate Value of substrate The value of the substrate at this stage of the process can be calculated by using the following table (generic values are given below). Cost ( ) Quantity lost Generic substrate values after trimming and binding Totals after press run Trimming and binding (time and overheads) Totals Table 4 Value of substrate after trimming and binding Sheet paper Paper roll Film roll and board 1.48/kg 4.10/kg 1.18/kg Wastebusting ideas Cutting too many sheets at a time can result in poor quality cuts and unsuitable edges. Errors can be avoided by ensuring that operators are aware of the maximum quantity of substrate that can be cut at one time. Ensure blades, knives and dies are sharp and make clean cuts. Introduce a procedure for checking blades and knives regularly. The need for trimming can be reduced by making sure that jobs fit reel and sheet sizes accurately. This is discussed in Section 3.1. When printing labels, ensuring that the label carrier material is a suitable size can reduce the need for trimming. Ensure that binding and stitching machines are lined up correctly and that sheets are loaded in the right order by including checking procedures at the binding stage. 14

20 3.6 COUNTING AND DELIVERY Ensuring the customer is supplied with the quantity of prints ordered and to the required quality is vital. Failure to do so can result in a job being returned and a re-run being requested. Therefore, it is important that the quantity of materials is correct, without supplying excessive overs, and that materials ready for dispatch are handled and packaged properly so that they are not damaged in transit. Typical wastes Over-counting/over-estimation. Damage to finished product. Returns. How to locate/quantify waste Keep job overs and set up a system to record quantity per job. Record where and why damage occurs. Keep a record of returns/dispatch notes Value of substrate The value of the substrate at this stage of the process can be calculated by using the following table (generic values are given below). Totals after trimming and binding Counting and delivery (time, materials and transport) Totals Cost ( ) Quantity lost Table 5 Value of substrate after counting and delivery Generic substrate values after counting and delivery Sheet paper Paper roll Film roll and board 1.50/kg 4.30/kg 1.21/kg Wastebusting ideas Counting Ensure that sheet counters are accurate - they are often set up to count out extra sheets. Periodic checks can counteract this problem. Any extras and overs can be kept for a period after the job has been delivered in case the customer wants to order more. This can save re-running the order and setting up the press again for a small run. Check customer requirements, as the specification may have changed. Delivery Deliver the finished product as quickly as possible to avoid the possibility of damage during storage prior to dispatch. The longer the product remains in the warehouse, the greater the risk of damage. As with storage of the raw material, it is important to protect the finished product from damage and dust. Wrapping and packaging the finished product in adequate materials can help ensure that the product will arrive at its destination in perfect condition. Ensure that storage conditions are correct for the finished product, to prevent deterioration while it awaits dispatch. Monitor the conditions in the dispatch area and the quality of the finished product. 15

21 3.7 OTHER AREAS Job planning Planning the order of print jobs in advance can increase the effective utilisation of the presses by reducing changeover periods or reducing the quantity of waste. By selecting the running order of jobs based on the colour of the ink, starting with light colour and moving to dark, the amount of cleaning can be reduced and hence press downtime. 3 A flexographic printer cut the working day from ten to eight hours by better planning. At a weekly planning meeting, the following week s running order is determined. Job running order is arranged based on ink colours, starting with jobs involving light colours and moving on to dark colours later. This reduces press cleaning time and degree of cleaning, with subsequent savings in solvent and energy. The reduction of 2 hours press time is equivalent to over /year (based on a figure of 60/hour), not including solvent savings. Experience is vital when printing difficult jobs. Build up a knowledge of difficult jobs and plan ahead to minimise waste, eg make a note of substrates and colours that cause problems. By assessing the complexity of a job and the presses available, savings can be made by running the job on the most appropriate press, eg run repeat orders on the same press and use newer presses for complex colour jobs. A company that prints packaging materials has six presses of various ages, so in planning jobs the age of the press determines the type of job to be done. The newer presses are used for print runs that use a range of colours, and will produce a better quality of print. Older presses are used to print jobs where positioning of the print is not so critical. This has helped to reduce wastage on press runs Quality systems The use of quality and environmental management systems such as the BS EN ISO 9000 series and ISO 14001, which introduce standardised procedures, can provide information to assist in: error checking; recording waste; identifying how damage occurs. Such information is useful when calculating the quantity of waste produced, identifying where wastage occurs and considering the reasons for the losses. The ability to identify how substrate is lost is the first step towards minimising and preventing such losses. The time and funds required for setting up a formal quality system are not always readily available. However, some of the principles of the quality system are easily incorporated into daily procedures. For example, a system for recording errors, or damage to the product on delivery or dispatch, can easily be set up. Information from the quality system can be fed back into the estimating/production system to correct any problems or areas of wastage that have been identified. A quality system can also assist in checking if a job has been costed correctly and where additional costs have been incurred. 16

22 A screen printing company has found that its greatest savings over the last five years have resulted from the implementation of a quality system (BS 5750 then ISO 9002) and an environmental management system (ISO 14001). The success of the quality systems was measured in terms of the number of credit notes issued to customers (a credit note was issued when a job was incorrect, hence a failure of quality checks). Since 1991 there has been a reduction in credit notes issued from 25 to 5 each month (or one a day to one a week). This is a reduction of 80% and has resulted in an increase in satisfied customers and significant substrate savings Credit notes Year General points Maintenance A good maintenance programme can reduce the number of press breakdowns and result in: a reduction in substrate losses; an increase in press utilisation. Staff training and awareness Staff training and awareness are as important as a good maintenance programme. A well-trained press operator will create less waste in set-up or slabbing off and take greater care with substrate if fully aware of the consequences. Set up a standard training scheme so that all press operators work through the same training procedure - this should reduce printing errors and thus waste. Encourage staff to come up with ideas, as they have experience in operating the equipment. Ensure that all staff are aware of the importance of minimising waste and the costs involved in creating waste. A lithographic printer has set up a special team to look at waste-related issues. Ideas and suggestions from the team have identified raw material savings of 1%. Recycling Recycling printed waste can save disposal costs and can also create a small revenue to offset the cost of the wasted material. Where possible segregate recyclable materials from general waste and arrange for collection by a local recycler. 17

23 4 NEW TECHNOLOGY Technology is continually advancing to offer quicker, more efficient printing methods. Many such advances can help reduce waste at all stages of the printing process. A selection of the technologies on offer are described in this Section - some are more expensive than others. In many cases, the initial investment will be recovered through savings in time, energy and raw materials, including substrates. 4.1 PRESS DESIGN Many new presses have built-in paper/substrate saving devices - key features are those that reduce edge trim, set-up waste and time. Large and small presses can include a combination of features: 4 semi-automatic/automatic plate changing; automatic ink cylinder wash-up; automatic lays pre-setting; automatic register pre-setting; print quality monitor; automatic blanket wash-up; automatic dampening control and pre-setting; automatic ink duct pre-setting; hickey picker; electronic fault diagnosis. If a short run-length is required, then a fast running speed is not necessarily a top priority - fast make-ready features are more important, eg semi-automatic plate changing, quick wash-up, fast registration and colour-up. A plate scanner may also be useful. Where short run-length and colour are important, there are some five and six colour variants on the market. In all cases, it is important to weigh up the full benefits, for example, quality, productivity, energy savings and maintenance, against the costs before investing in expensive equipment. 4.2 COLOUR MATCHING/COMPUTERISED SET-UP/PRINT MONITORING Ink colour matching and formulation systems can save money, reduce wastage and cut down on the amount of ink needed, and thus the time spent in set-up/make-ready. The cost of the system can be recovered in substrate and ink savings. Computerised systems are particularly useful in enabling a press operator to match colours to be printed and duplicate colour matches time after time - especially for repeat orders. They are equally useful in monitoring print quality during the press run. A computerised scanning system can compare the printed sheet against a proof, and will alert the press operator when any problems or mismatches occur. 18

24 4.2.1 Densitometers Densitometers measure the density of an ink layer on a surface by shining a light on it and from the amount of light reflected back, calculate the concentration of ink. These save money by reducing set-up/make-ready time and maintaining consistency throughout a print run. Different types include: reflection densitometer - assesses plate dot characteristics; transmission densitometer - measures transmitted light not reflected light (for use on film); scanning densitometer - takes a higher throughput than an ordinary reflection densitometer Spectrophotometers Spectrophotometers are relatively new to the printing industry and are used to control the printing of extra colour Viewing booths Viewing booths provide a colour-corrected environment in which to check printed sheets against proofs; some booths have backlit areas. 4.3 INK SYSTEM Inks can assist in reducing make-ready, cleaning, breakdowns, colour changes and substrate wastes, eg ultraviolet cured ink in screen printing (see Good Practice Case Study (GC88) UV Inks Save Screen Printer Time and Money, available free of charge through the Environmental Helpline on ) DAMPENING SYSTEMS In lithographic printing the trend is for larger, faster running machines. Traditional plate dampening systems are not always suitable for this application. This has led to the development of a range of modified dampening systems that minimise wastage on larger, faster running machines. 4.5 ADVANCED MECHANICAL HANDLING EQUIPMENT Mechanical handling equipment can reduce the risk of damage to substrate during handling and enable larger reels to be used for print runs. This equipment includes: conveyor belts; automatic press loading; overhead winder loading; automatic fork lift system (ABV). 4.6 STATIC ELECTRICITY REDUCTION Static electricity is a particular problem when handling plastics. The investment cost of an electrostatic elimination system can be paid back by savings from reduced stoppages and an improvement in machine production. Different types of system are available including ionisation heads and static eliminators. Benefits of electrostatic charging systems include: edge pinning of plastics to prevent slippage; increased production speeds; improved quality; and reduced number of rejects. 19

25 5 ACTION PLAN Now you have read this Guide, the next step in the process of reducing substrate losses is to draw up an Action Plan. The Action Plan should include the following steps: 5 Identify a waste reduction co-ordinator. Set up a waste reduction team. Identify the quantity of substrate lost. Audit the stages in your process to determine where and why substrate losses occur. Calculate the cost of the substrate lost (including any hidden costs). Identify any methods of reducing the losses (using appropriate options from the information in Sections 3 and 4). Implement the options, perhaps by placing targets on teams. Monitor performance. Record cost savings achieved. 20

26 Appendix SAMPLE WORKSHEETS The following blank forms are intended for you to photocopy and use in your own company. Worksheet 1 (Fig A1) can be used to calculate costs and wastage for each printing job (Fig 2 on page 4 is an example of a completed worksheet). Worksheet 2 (Fig A2) can be used to calculate costs at each stage of the printing process (Fig 3 on page 6 is a worked example). Following the introduction of waste reduction methods, the worksheets can be used to monitor performance. appx A1 21

27 JOB SUMMARY Job description Press used Type of substrate No. of colours PRODUCT DETAILS Print run Quantity printed Quantity dispatched Quantity of overruns/overs SUBSTRATE DETAILS Substrate quantity issued Substrate quantity Substrate quantity in Substrate quantity* for job* in all finished product dispatched* in overruns/overs** product* COST SUMMARY Total quantity Unit value Total cost or measure ( /quantity) ( ) (kg, hours, etc) Substrate ordered or issued for the job x = appx A1 Other materials issued (ink, solvent, plates, etc) x = Press time (the cost of running the press for a set period of time) hours x = Staff time: estimating and ordering hours x = trimming and binding hours x = counting and delivery hours x = TOTAL COST OF JOB Unit value of = Total cost of job =... =.../(sheet, m, kg) finished product Substrate quantity issued for job Cost of substrate = (quantity of substrate issued for job quantity dispatched) x unit value losses =... = * Usually a weight (kg) determined by weighing/calculating substrate and product, but other consistent measures can be used (eg sheets, metres, rolls). ** This can be used to assess substrate used in overruns/overs (extra items above the agreed total ordered) and monitor excessive production. Count as waste any which the customer does not receive. Fig A1 Worksheet 1 - calculating costs and wastage by job 22 GG107 Published by the Environmental Technology Best Practice Programme Environmental Helpline

28 Estimating (time) Ordering (time) Handling and storage Substrate Totals Cost ( ) Quantity lost Quantity left after stage = Quantity ordered Quantity lost = Total cost Unit cost of substrate after storage = = Quantity left after stage Cost of waste after storage = Unit cost x Quantity = Table 1 Value of substrate after estimating, ordering, storage and handling Totals after estimating, ordering, etc Set-up (time and materials) Cost ( ) Quantity lost Unit cost of substrate after set-up = Cost of waste after set-up = Totals Table 2 Value of substrate after set-up/make-ready Totals after set-up Cost ( ) Quantity lost Unit cost of substrate after press run = Press run (press time/downtime) Cost of waste after press run = Totals Table 3 Value of substrate after press run Cost ( ) Quantity lost Totals after press run Unit cost of substrate after trimming, etc = Trimming and binding (time and overheads) Totals Cost of waste after trimming, etc = appx A1 Table 4 Value of substrate after trimming and binding Totals after trimming and binding Counting and delivery (time, materials and transport) Totals Cost ( ) Quantity lost Table 5 Value of substrate after counting and delivery % of sheets/rolls lost = Total quantity lost x 100 = Quantity ordered Unit cost of substrate after delivery = Cost of waste after delivery = Cost of waste = Fig A2 Worksheet 2 - calculating costs at each stage of the printing process GG107 Published by the Environmental Technology Best Practice Programme Environmental Helpline

29

30 The Environmental Technology Best Practice Programme is a joint Department of Trade and Industry and Department of the Environment, Transport and the Regions programme. It is managed by AEA Technology plc through ETSU and the National Environmental Technology Centre. The Programme offers free advice and information for UK businesses and promotes environmental practices that: increase profits for UK industry and commerce; reduce waste and pollution at source. To find out more about the Programme please call the Environmental Helpline on freephone As well as giving information about the Programme, the Helpline has access to a wide range of environmental information. It offers free advice to UK businesses on technical matters, environmental legislation, conferences and promotional seminars. For smaller companies, a free counselling service may be offered at the discretion of the Helpline Manager. FOR FURTHER INFORMATION, PLEASE CONTACT THE ENVIRONMENTAL HELPLINE address: etbppenvhelp@aeat.co.uk world wide web: