How can heatset printers reduce waste?
Paper waste is a significant concern in heatset printing, particularly because these presses run at high speeds. The article gives an indicative figure of up to 15% paper waste in offset printing. Unmanaged waste places a financial burden on printers. The first step is to identify its causes, so they can be measured and controlled.
Sources of paper waste in offset printing
The source gives these indicative ranges for different causes of waste; they depend on the job and operating conditions:
• Cutting waste from a mismatch between imposition and the chosen sheet size: 5–10%.
• Storage waste associated with unsuitable storage temperatures: 0.5%.
• Damage during reel handling, loading and unloading: 1%.
• Reel-end waste, which operator training can help minimise: 1%.
• Make-ready waste, including colour adjustment and washing: 2–10%.
• Folding waste and edge trimming for binding: 1–2%.
Using an appropriate heatset ink is one way to reduce waste. If its water uptake and tack do not suit the printing conditions, press adjustment takes longer and the high running speed generates more waste sheets. An ink that reaches a stable balance more quickly on a web offset press can shorten make-ready, reduce paper waste and lower job costs.
Poor-quality heatset inks can also cause problems in the dryer. Vapours from evaporating ink additives may increase energy use and environmental burdens and leave deposits on the dryer body, exhaust and ducts. Over time, these deposits can obstruct outlets and impair drying.
A suitable, well-formulated heatset ink can therefore help reduce both paper waste and wasted energy.