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

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.  

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