Miscalculating necessary bindery spoilage into your printing run has a huge negative financial impact for many people. Your customer ends up not getting the number of products they ordered, and that puts the salesperson in a “negative call” situation. As a printer, you were not able to have all of your cost paid for, because those were allocated over the entire production run, but the job is short. As a finisher, we are out the opportunity to charge for services as well, because we have unfinished product on our floor, usually missing only one component. It really is a very unfortunate situation that needs to be taken into consideration during the planning stage of a job, prior to printing.
CALCULATING SPOILAGE
Whether your project is a simple self-mailer or a multi-component marketing piece, it will likely go through several post press production steps prior to completion. Consider the processes required to create even a basic pocket folder: die cutting, stripping, folding and gluing.
| BASED ON FINISHING OPERATIONS |
|
Operation |
Set-Up
# of Sheets |
Plus Spoilage |
|
Cutting |
50 |
1/2% |
|
Folding |
100 |
1 1/2% |
|
Stitching |
250 |
2% |
|
Adhesive Binding |
350 |
3% |
|
Remoistenable Glue |
500 |
3 % - 5 % (depending on fold complexity) |
|
Punching |
100 |
3% |
|
Drilling |
50 |
2% |
|
Tab Cutting |
50 |
2% |
|
Die Cutting |
150 |
2% - 4% |
|
Pocket Folder Gluer |
300 |
4% |
|
In-Line Ink Jetting |
200 |
2% |
To calculate how many pieces you'll need to reach your desired quantity, you must determine how much spoilage each production process will consume. A spoilage rate chart, such as the one shown above, can be used to quickly calculate how much spoilage each process will require. Note that these spoilage rates are expressed as a percentage of a given quantity.
Keep in mind that spoilage is cumulative. To calculate an accurate production quantity, you will need to determine the spoilage rates from each production process and add them together. Be sure to account for set up sheets in your spoilage equation as well.
Complex projects may require additional spoilage factors – A particular intricate die cut or complex fold may render “standard” spoilage rates a bit conservative. If that's the case with your project, we will help you calculate a more realistic production quantity.
Spoilage rates are based on industry averages and vary little between providers. However, a post press services company that can perform a complete range of bindery and finishing services under one roof can usually keep spoilage to a minimum by minimizing handling and transportation. These advantages can add up to fairly substantial savings in both time and money as quantities climb.
Please feel free to contact us if you need further clarification, or would like some additional information.
