How do you calculate ink consumption in flexo printing? | Keshenglong&Shinko Guide

How Do You Calculate Ink Consumption in Flexo Printing?

Accurately calculating flexo printing ink consumption is crucial for cost control and efficient production. Many printers struggle to predict ink usage precisely, leading to waste and unexpected expenses. This article provides a practical guide to help you master ink consumption calculations in your flexo printing operation.

Understanding the Variables

Accurate ink consumption calculation relies on understanding several key variables. These include:

Substrate Area: The total surface area of the substrate (e.g., film, paperboard) to be printed. This is calculated based on the width and length of the material run.

Ink Coverage: This refers to the percentage of the substrate covered by ink. Solid areas will have 100% coverage, while screens and halftones will have lower percentages. This is often expressed as a percentage.

Ink Density: The concentration of pigment in the ink. Higher density inks require less volume to achieve the desired color.

Print Speed: The speed of the press directly impacts ink usage. Faster speeds generally mean slightly higher consumption due to increased transfer.

Anilox Roll Specifications: The volume and cell geometry of your anilox roll significantly affect ink transfer. Higher BCM (cubic meters per square meter) rolls deposit more ink.

Ink Viscosity: Thicker inks require more pressure and may lead to increased consumption.

Calculating Ink Consumption

The basic formula is:

Total Ink Consumption = (Substrate Area x Ink Coverage x Ink Density) / Anilox Roll BCM

Example:

Let's say you're printing on a substrate with a total area of 1000 square meters, targeting 60% ink coverage, using an ink with a density of 1.2 g/cm³, and an anilox roll with a BCM of 6 cm³.

Total Ink Consumption = (1000 m² x 0.6 x 1.2 g/cm³) / 6 cm³ ≈ 120 kg

Important Note: This is a simplified calculation. Factors like press setup, ink viscosity, and substrate absorbency can affect the actual ink usage. It's crucial to consider these when making more precise estimations. Furthermore, consider adding a buffer for waste or unforeseen circumstances.

Refining Your Calculations

For more precise results, consider these points:

Conduct Test Runs: Perform test runs on different substrates with your specific setup before large-scale production to calibrate your calculations.

Monitor and Track: Maintain detailed records of ink usage for each job, including all variables mentioned earlier. This data allows you to refine your calculations over time.

Regular Anilox Roll Maintenance: Ensure your anilox rolls are properly maintained and cleaned. Worn or damaged rolls can significantly impact ink transfer and increase consumption.

By diligently tracking variables and employing the formula above, you can greatly improve your ability to predict and control flexo printing ink consumption, leading to significant cost savings and enhanced efficiency.