(On-Site Ink Management Offers Spectrum of Benefits, But is it right for your box plant?)
Today's corrugated paper industry is constantly changing and developing. The user's requirements and high technology have brought it an irresistible demand boom. A number of corrugated board printing plants have adopted a site ink management system to realize a work process with reduced costs and increased added value.
Before exploring the trends in this workflow in detail, let us first understand what a live ink management system is. Sometimes, we will find that many corrugated board printers use their own production of ink instead of the purchased ink to print the finished product. They turn ink production into a part of the entire factory production process. In fact, this is an integral part of the on-site ink management system.
Taken as a whole, an on-site ink management system consists of many parts. Including color matching, color verification, ink use arrangements, inventory management, the use of surplus ink to improve economic efficiency and production costs, ink reuse number forecast, a variety of records management, ink deployment and customer feedback, etc. Aspects of content. This is not the way to work for every vendor. Many factors must be considered before deciding to use an on-site ink management system. They include, but do not only include, the following aspects:
[1] Confusion of printed products
[2] General and Special* Special Ink Types * Color Stability of Special Ink Needed * Important timing, when to use special inks
[3] Inventory Status and Future Plans * Inventory Quality - Useful and Obsolete Proportions
[4] The real cost difference between homemade ink and out of ink
[5] Whether the entire system has enough space arrangements, including:
*Laboratory* Inkjet machine* Raw materials and finished product storage
A "work report" prepared for this particular job
Unpredictable value of the system
Detailed discussion
The degree of mixing of printed products ----- General and special Under normal circumstances, in the on-site ink management system, corrugated flexible printing aqueous ink generally does not include the production of GCMI standard inks. Of course, there are exceptions if you can save a lot of costs.
An inking machine (automatic or manual) uses basic materials and ingredients to modulate the finished ink. Depending on the situation, such as the type of press, the base composition, and the finished product requirements (grinding or glossy, etc.), many ingredients may be needed, but in most cases, only one color base material is sufficient. This color base plus varnish must be able to complete most of the required ink modulation.
If you want to make GCMI standard inks on the spot, the same material is used for the color base, but the varnish can use less expensive products. But if you only produce a little bit, then its cost will not be lower than the manufacturer's 15,000 to 30,000-pound mass production.
Therefore, when the ink is distributed on the spot, it is best to manufacture special inks, and it is also necessary to know the number and type of production. A factory may require 200,000 pounds of expensive specialty inks, but it is not necessarily worth establishing a site ink system because the 200,000 pounds of ink may contain only six to seven colors.
But if this 200,000 pounds of ink is divided into 120 colors, and 40 to 50 of the major colors are used frequently, then this system is worth considering. Confusion is a prerequisite because it often requires a lot of special colors. If there are more, and the amount of each color is not large, but two to five bags, then the on-site ink system is useful.
Now let's look at another issue related to these special inks: Inventory
The current status and use of inventory inks can create a potential loss for manufacturers, if these inks are “annihilated†or “hibernateâ€. Many times, people use outdated ink or printed ink to make black ink. This is indeed no waste, but it is not the best way to use it. If you need a lot of special inks for printing, you should almost have a part of the ink that can't be used anymore. You should know what this means. You also need to know how to use these old inks, and even those that are left over from printing.
An ink-jet machine, especially an automatic ink-jet machine, will bring convenience to your own ink. It will make you accustomed to make your own special inks and start a small amount of production. The "useless" color inks will also decrease. In this way, after a non-repetitive printing job is completed, the remaining special ink will be few and your warehouse will be better managed. In the best case, all the special colors will be used up. There will be almost no remaining ink, and the printing ink will become extremely rare.
If the color matching management is implemented by a computer and used with an automatic ink-dispenser, the “useless†ink and the printed ink can be used to make special inks of Other colors. These inks are sold on the market 3/ $2 per pound, but black ink is only 60 cents?
Inventory will be further illustrated in the text later. We will discuss the cost of homemade ink and market purchase.
Choosing a home-made ink should be cheaper than buying it directly from an off-the-shelf ink supplier because the off-the-shelf product contains the manufacturer's processing costs. How can it be calculated?
The best way is to find some ready-made special color inks, 6 to 12 kinds are more appropriate, and then ask your ink supplier what basic materials and varnish to make this color. How much is the cost of each kind of raw material? After that, the average cost savings will be multiplied by the amount you used to get a total cost savings that you can make at home.
Space arrangement of the entire system When establishing an on-site ink management system, must the factory space be determined? how many? Is it enough? The on-site ink management system cannot eradicate the inventory and can only be minimized, because the GCMI color ink, the remaining ink, the base material, the empty bucket, the ink drum, etc. needed for printing need to be stored. It is used with a uniform ink machine and a laboratory. Like workplaces, they are all part of the entire system and must be counted together. However, this part of the work is not difficult, but it should be completed earlier.
Work Reports As previously mentioned, on-site ink management does not only refer to ink production. An ink-jet printer can provide a lot of useful information and save the required data according to application software requirements. This information includes the use of various colors of ink, the cost of work, the cost of basic materials, the remaining amount of ink, VOC, HAP indicators and other relevant data, etc. It provides useful help for people to better understand and manage the entire work.
Unpredictable value This value is different for each company. A good leveling machine, laboratory, color control computer, portable work warehouse, automatic calibration system, qualified operators, etc. will show strong advantages, and they can calmly deal with some unintended things. For example, the job changed to another completely different printing press, or replaced the film base in the last second and so on. If you reduce this type of downtime by three to five hours a week, how much is it?
Of course, tracking and analyzing these data will also be calculated and taken into account when adding on-site ink management systems. However, because each factory is not consistent, it is necessary to analyze specific issues before we can understand the value of this part. How many.
case:
* I spent $630,000 a year to buy 200,000 pounds of special ink, about 100 colors, some of which are often replaced.
* My inventory is 600,000 pounds, of which 200,000 pounds are GCMI inks and 4 million pounds are specialty inks. It is estimated that the 200,000 pounds of GCMI ink will use up light, but will leave 250,000 pounds of specialty inks that may not be used anymore.
* We purchased 10 kinds of special inks and matched them with basic materials and varnish. According to the price of basic materials, we calculated that we could save about 12% of the price compared with the purchase of special inks in the market.
* Our marketing manager and general manager also agreed that the use of computerized color-controlled automation systems will attract new users. But if it is not absolutely necessary, we will not calculate it by the value it brings.
Everything must be analyzed separately. The cost of ink jets varies, as does the cost of laboratories and personnel. There is no food to eat under the sun. No matter if you add ink, or if your supplier buys it, or hires you, or your supplier hires, you have to pay for it. Only in different situations will save some costs.
Based on the past years of working in the corrugated paper industry, Sun Chemical has indeed seen many of the benefits of using this on-site method of producing ink—saving costs. Of course, there are some exceptions, that is, using this method is not from the perspective of cost savings, the addition of ink distribution equipment may be other reasons. Unforeseen value is also a benefit that this system can bring, but it should be treated with caution.
One thing needs to be emphasized: some inks cannot be produced at the scene. For example, the standard 12 to 16 sets of ink presses do not have a low copper base material position, so when printing requires low copper ink, it is necessary to go to the market to purchase. The same is true for metallic inks and fluorescent inks. Although this kind of ink is only a small part, it is very important, so you must know what you can or cannot make. Of course, you can also think about advanced GCMI color inks if you're cheap at the scene.
Is the on-site ink system right for you? You must take this issue seriously and take the time to think carefully. This will greatly help your future work.
Note: All data in this article is for illustrative purposes only and does not represent the true price of each or each product.
Related economic points
Cost savings:
Ink savings: 630,000 × 12% = $75,600
Inventory savings:
* 25,000 pounds of unused ink per year
*For making black ink: 25,000 × 0.60=15,000 USD
* When made into other colored inks: 25,000 x 3.15 = $78,750
* Savings through colored inks: $63,750
Cost: (Think system is purchased from the market)
Ink machine = $60,000
* Annual depreciation = 23,000 USD
Construction laboratories cost = $45,000 (including operating room and equipment)
* Annual depreciation = $ 17,000
Annual staff cost = $60,000 Total cost (savings) = $39,350
Today's corrugated paper industry is constantly changing and developing. The user's requirements and high technology have brought it an irresistible demand boom. A number of corrugated board printing plants have adopted a site ink management system to realize a work process with reduced costs and increased added value.
Before exploring the trends in this workflow in detail, let us first understand what a live ink management system is. Sometimes, we will find that many corrugated board printers use their own production of ink instead of the purchased ink to print the finished product. They turn ink production into a part of the entire factory production process. In fact, this is an integral part of the on-site ink management system.
Taken as a whole, an on-site ink management system consists of many parts. Including color matching, color verification, ink use arrangements, inventory management, the use of surplus ink to improve economic efficiency and production costs, ink reuse number forecast, a variety of records management, ink deployment and customer feedback, etc. Aspects of content. This is not the way to work for every vendor. Many factors must be considered before deciding to use an on-site ink management system. They include, but do not only include, the following aspects:
[1] Confusion of printed products
[2] General and Special* Special Ink Types * Color Stability of Special Ink Needed * Important timing, when to use special inks
[3] Inventory Status and Future Plans * Inventory Quality - Useful and Obsolete Proportions
[4] The real cost difference between homemade ink and out of ink
[5] Whether the entire system has enough space arrangements, including:
*Laboratory* Inkjet machine* Raw materials and finished product storage
A "work report" prepared for this particular job
Unpredictable value of the system
Detailed discussion
The degree of mixing of printed products ----- General and special Under normal circumstances, in the on-site ink management system, corrugated flexible printing aqueous ink generally does not include the production of GCMI standard inks. Of course, there are exceptions if you can save a lot of costs.
An inking machine (automatic or manual) uses basic materials and ingredients to modulate the finished ink. Depending on the situation, such as the type of press, the base composition, and the finished product requirements (grinding or glossy, etc.), many ingredients may be needed, but in most cases, only one color base material is sufficient. This color base plus varnish must be able to complete most of the required ink modulation.
If you want to make GCMI standard inks on the spot, the same material is used for the color base, but the varnish can use less expensive products. But if you only produce a little bit, then its cost will not be lower than the manufacturer's 15,000 to 30,000-pound mass production.
Therefore, when the ink is distributed on the spot, it is best to manufacture special inks, and it is also necessary to know the number and type of production. A factory may require 200,000 pounds of expensive specialty inks, but it is not necessarily worth establishing a site ink system because the 200,000 pounds of ink may contain only six to seven colors.
But if this 200,000 pounds of ink is divided into 120 colors, and 40 to 50 of the major colors are used frequently, then this system is worth considering. Confusion is a prerequisite because it often requires a lot of special colors. If there are more, and the amount of each color is not large, but two to five bags, then the on-site ink system is useful.
Now let's look at another issue related to these special inks: Inventory
The current status and use of inventory inks can create a potential loss for manufacturers, if these inks are “annihilated†or “hibernateâ€. Many times, people use outdated ink or printed ink to make black ink. This is indeed no waste, but it is not the best way to use it. If you need a lot of special inks for printing, you should almost have a part of the ink that can't be used anymore. You should know what this means. You also need to know how to use these old inks, and even those that are left over from printing.
An ink-jet machine, especially an automatic ink-jet machine, will bring convenience to your own ink. It will make you accustomed to make your own special inks and start a small amount of production. The "useless" color inks will also decrease. In this way, after a non-repetitive printing job is completed, the remaining special ink will be few and your warehouse will be better managed. In the best case, all the special colors will be used up. There will be almost no remaining ink, and the printing ink will become extremely rare.
If the color matching management is implemented by a computer and used with an automatic ink-dispenser, the “useless†ink and the printed ink can be used to make special inks of Other colors. These inks are sold on the market 3/ $2 per pound, but black ink is only 60 cents?
Inventory will be further illustrated in the text later. We will discuss the cost of homemade ink and market purchase.
Choosing a home-made ink should be cheaper than buying it directly from an off-the-shelf ink supplier because the off-the-shelf product contains the manufacturer's processing costs. How can it be calculated?
The best way is to find some ready-made special color inks, 6 to 12 kinds are more appropriate, and then ask your ink supplier what basic materials and varnish to make this color. How much is the cost of each kind of raw material? After that, the average cost savings will be multiplied by the amount you used to get a total cost savings that you can make at home.
Space arrangement of the entire system When establishing an on-site ink management system, must the factory space be determined? how many? Is it enough? The on-site ink management system cannot eradicate the inventory and can only be minimized, because the GCMI color ink, the remaining ink, the base material, the empty bucket, the ink drum, etc. needed for printing need to be stored. It is used with a uniform ink machine and a laboratory. Like workplaces, they are all part of the entire system and must be counted together. However, this part of the work is not difficult, but it should be completed earlier.
Work Reports As previously mentioned, on-site ink management does not only refer to ink production. An ink-jet printer can provide a lot of useful information and save the required data according to application software requirements. This information includes the use of various colors of ink, the cost of work, the cost of basic materials, the remaining amount of ink, VOC, HAP indicators and other relevant data, etc. It provides useful help for people to better understand and manage the entire work.
Unpredictable value This value is different for each company. A good leveling machine, laboratory, color control computer, portable work warehouse, automatic calibration system, qualified operators, etc. will show strong advantages, and they can calmly deal with some unintended things. For example, the job changed to another completely different printing press, or replaced the film base in the last second and so on. If you reduce this type of downtime by three to five hours a week, how much is it?
Of course, tracking and analyzing these data will also be calculated and taken into account when adding on-site ink management systems. However, because each factory is not consistent, it is necessary to analyze specific issues before we can understand the value of this part. How many.
case:
* I spent $630,000 a year to buy 200,000 pounds of special ink, about 100 colors, some of which are often replaced.
* My inventory is 600,000 pounds, of which 200,000 pounds are GCMI inks and 4 million pounds are specialty inks. It is estimated that the 200,000 pounds of GCMI ink will use up light, but will leave 250,000 pounds of specialty inks that may not be used anymore.
* We purchased 10 kinds of special inks and matched them with basic materials and varnish. According to the price of basic materials, we calculated that we could save about 12% of the price compared with the purchase of special inks in the market.
* Our marketing manager and general manager also agreed that the use of computerized color-controlled automation systems will attract new users. But if it is not absolutely necessary, we will not calculate it by the value it brings.
Everything must be analyzed separately. The cost of ink jets varies, as does the cost of laboratories and personnel. There is no food to eat under the sun. No matter if you add ink, or if your supplier buys it, or hires you, or your supplier hires, you have to pay for it. Only in different situations will save some costs.
Based on the past years of working in the corrugated paper industry, Sun Chemical has indeed seen many of the benefits of using this on-site method of producing ink—saving costs. Of course, there are some exceptions, that is, using this method is not from the perspective of cost savings, the addition of ink distribution equipment may be other reasons. Unforeseen value is also a benefit that this system can bring, but it should be treated with caution.
One thing needs to be emphasized: some inks cannot be produced at the scene. For example, the standard 12 to 16 sets of ink presses do not have a low copper base material position, so when printing requires low copper ink, it is necessary to go to the market to purchase. The same is true for metallic inks and fluorescent inks. Although this kind of ink is only a small part, it is very important, so you must know what you can or cannot make. Of course, you can also think about advanced GCMI color inks if you're cheap at the scene.
Is the on-site ink system right for you? You must take this issue seriously and take the time to think carefully. This will greatly help your future work.
Note: All data in this article is for illustrative purposes only and does not represent the true price of each or each product.
Related economic points
Cost savings:
Ink savings: 630,000 × 12% = $75,600
Inventory savings:
* 25,000 pounds of unused ink per year
*For making black ink: 25,000 × 0.60=15,000 USD
* When made into other colored inks: 25,000 x 3.15 = $78,750
* Savings through colored inks: $63,750
Cost: (Think system is purchased from the market)
Ink machine = $60,000
* Annual depreciation = 23,000 USD
Construction laboratories cost = $45,000 (including operating room and equipment)
* Annual depreciation = $ 17,000
Annual staff cost = $60,000 Total cost (savings) = $39,350
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