Calculate Flexo Press Savings Provided by a Servo Add On

By eliminating the inefficiency of flexographic printing operations, you can save on lost materials and labor while setting up, repairing, and re-launching printing jobs. The flexographic printing press is associated with overheads associated with its operation, and these overheads are saved regardless of whether the machine works efficiently or not. The most efficient use of a flexographic printing press increases profits while maintaining a static charge.

What are the cost savings of the press?

The flexographic press, equipped with an auxiliary servopress, registers the length of the press material. This is the minimum for any press. A standard flexographic printing press, which is not equipped with a re-registration servo and a feed system offered by an additional servo, will usually have much more waste than a powered press.

Reducing the length of a flexographic printing press to the length of a printing press is just one way to save money with a servo. Color “shrinkage” is a common occurrence when a printing press picks up speed. At variable tension of the tape, the material will stretch or fold, and the colors will wander on the tape until the press reaches speed and resumes recording. All this can take much longer than just the press! Each time a roll is replaced, the waste matrix is removed, or the separated material is moved through a standard press, it must be restarted, and the same shrinkage problem occurs with the used media.

The excellent tension of the canvas, supported by an additional servo, allows the flexographic press to serve the roll to the core. In addition, the servo saves time and material. This discussion is only about calculating press savings. It does not address many other benefits of using a servo add-on that allows the printing press to print on a wider range of substrates, or complex tasks such as printing or layering labels or printing on a digital printing machine.

What do you need to do to calculate the savings?

Check out the extended version of this discussion with a savings calculator that will simplify your work. Information and calculator in English and Spanish. You enter information about your company into the calculator. You will know a lot, and some will have to watch the actions of the press and take action.

How much material is in the press of the first printing house?

To determine this when the press is stopped, mark the roll when the products are re-winding and mark the canvas with a marker on the first printed section. Wait until the label is fast-forwarded. Remove the material between the label and the flag by hand. Measure the material with roulette.

How much material is wasted on getting the press on the roster after the reboot?

To determine this when the press is stopped, mark the roll when the product is re-winding. Start the press until it registers again, and rewind the product a second time. Remove the material between the flags by hand and measure it with roulette.

Definitions and formulas

Daily savings

Images are stored daily (feet were wasted to get pressure in the register – feet of material when printed) x stops per shift x shifts per day

The cost of images stored daily is the cost of one MSI x MSI stored daily

Daily BACK up MSI q images stored daily x web page width ÷ 1000

Saved time/minutes – daily stored records ÷ average print speed

Additional cost savings – Pressure overload ÷ 60 x minutes saved

Summary: Forecasts are based on a 20-day working month and a 40-hour shift. All time calculations are translated into hours.

With the savings calculator, you enter the following information:

Cost per MSI
Press overhead/ hour
Strap width (inch)
Average FPM press speed
Press material (legs)
Material used for recording (feet)
Click Start as a Team
Shift per day

To get data on daily savings:

Daily material savings


Daily savings


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