How Digital Frame Calculation Works on a Press

How Digital Frame Calculation Works on a Press


Click Charge

HP ‘Smart Planner’ software calculates the click rate as follows:-


1 “frame” = 980mm (Circumference of blanket cylinder)

Gap along = 3mm

Labels per frame = Floor (980 / (FinLen + 3) )

Frames = job quantity / labels per frame

Impressions = frames * colours 


Example: 30,000 labels 200mm wide  x 100mm deep 4 cols

Labels per frame = 980 / (100 + 3) = 9.514 rounded down (floor) to 9

Frames = 30,000 / 9 = 3334

Impressions = 3334 * 4cols = 26,672 @ $0.02 = $533.44

The blanket cylinder is 980mm circumference. The cylinder does a single revolution on the paper, and then the paper is drawn back for the 53mm to align with the next label, leaving no image gap.  
HP Charges per revolution, regardless of image area.



This will cause a huge variation in price for a minor variation in size: 

Example  a) 30,000 4 cols 200 x 240mm 

b) 30,000 4 cols 200 x 243mm



980 / (240+3) = 4 labels per frame. 

30,000 / 4 = 7500 frames * 4 cols @$0.04 = $1200



980 / (243+3) = 3 labels per frame. 

30,000/3 = 10000 frames * 4 cols @$0.04 = $1600


A 3mm variation in label size has resulted in a frame qty increase of 33%, or $400 for an additional 90M in this example.



Speed Calculation


A single 980mm frame impression prints a variable image size, the paper drawn back to close the gap.

At a constant impression speed, a smaller frame image will take longer to print the same linear Metres (fewer M/hr)

Using the above illustrated examples at a constant speed of 1000 frames/hr:-


Example 1: 30,000 Labels 100 x 243mm; 2 across; 3645 linear meters to print

Labels per impression = 8; Total imps = 3750

3750/1000 = 3.75hrs

3645m / 3.75hrs = 972M/hr


Example 2: 30,000 Labels 100 x 246mm; 2 across; 3690 linear meters to print

Labels per impression = 6; Total imps = 5000

5000 / 1000 = 5hrs

3690m / 5hrs = 736M/hr





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