Ink & Ink Dispensers


Quantifying ink consumption per job: unlocking the value of data in package printing


ByMaarten Hummelen, marketing director, GSE


he ability to accurately calculate, predict and measure the amount of ink required for a packaging print run is vital from both production and strategic perspectives. As converters move toward digitalised, data-led workfl ows, knowing how much ink is used per job has become critical. Ink consumption data underpins accurate costing, environmental reporting, press performance monitoring and inventory planning. Yet most printers can only make rough estimates of their ink consumption rather than obtain measurable values. For printers using liquid inks such as those formulated for fl exo, gravure and screen processes, calculating ink-use per print run is complex, depending on multiple variables. Furthermore, accessing this data is often cumbersome unless diff erent MIS systems can exchange information. To gain meaningful insight, converters need a solution that not only calculates consumption quickly but also stores and shares that data within an integrated network.


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WHY INK CONSUMPTION IS DIFFICULT TO CALCULATE


Ink consumption in fl exo and gravure depends on numerous interacting factors: • Run length and print quantity • Print area and percentage of coverage in the design • Ink absorption, infl uenced by substrate type, coatings and ink layer thickness


• Ink transfer effi ciency, as a portion remains in the anilox cells or on the plate


• Ink set characteristics, with solvent and water-based inks losing weight through evaporation, unlike UV inks


• Minimum ink volume needed in the chamber, fountain, or squeegee for operation Each variable aff ects the others, making accurate prediction by formula alone impossible.


THE RISKS OF RELYING ON ‘GUESSTIMATES’ AND INTUITION


Without reliable data, ink technicians often prepare a margin of safety - slightly more ink than they believe the job requires - to avoid stoppages caused by shortfalls. While practical, this approach drives up waste and working capital and clutters storerooms with leftover inks awaiting reuse.


Dependence on the intuition of experienced staff also introduces risk. When key personnel are


16 October 2025


unavailable, or new recruits take over, consistency suff ers. Guesswork can keep production running, but it prevents accurate costing and obstructs long-term performance improvement.


TURNING MEASUREMENT INTO A MANAGED PROCESS


Modern ink management software transforms ink prediction from guesswork into a measurable, repeatable process. Ideal for packaging and label printers handling repeat orders, such systems calculate the required ink weight for each printing station using stored press data and job parameters. The software relies on three core datasets:


1. Job data – design dimensions, coverage percentages, substrate type and run length.


2. Press confi guration data – minimum fi ll weights for each station, anilox specifi cations and mechanical settings.


3. Ink data – colour recipes, density and coating weight per square metre.


By combining these inputs, the system instantly calculates the theoretical ink requirement for each colour. When the order is repeated, ink weight data can be recalled easily for dispensing. After production, reporting tools store ink consumption data, allowing comparisons of planned versus actual use.


THE ADVANTAGES OF AUTOMATED CONSUMPTION CALCULATION


Software-based ink management delivers measurable benefi ts across production and business functions: • Accurate costing and quoting – job estimates are based on data, not averages.


• Reduced waste – ink preparation aligns with actual print-run needs.


• Better sustainability reporting – emissions, waste and recycling rates can be tied to specifi c jobs.


• Process improvement – historical data highlights ineffi ciencies in coverage, anilox choice, or setup.


• Improved inventory control – stock levels and purchasing plans refl ect real usage.


• More effi cient use of staff time – automation frees skilled operators for higher-value work.


MAKING INK CONSUMPTION DATA ACTIONABLE


Collecting data is one thing; using it eff ectively is another. For maximum value, ink data should integrate with broader business systems such


as production planning, costing and quality management. Specialist software that tracks ink’s non-linear route through the printshop enables consumption data to be connected to job and inventory records. Key points for recording include the moment of dispensing and when returned inks are weighed in. Integration modules allow seamless data exchange between colour management, ink management and MIS platforms, creating a single, reliable view of material usage.


Technology, however, is only part of the solution. To unlock its full potential, converters must maintain discipline in data recording, encourage staff engagement with measurement processes and establish regular feedback loops comparing planned and actual consumption. A culture of collaboration and visibility ensures that insights are shared across departments, supporting evidence-based decision- making.


FROM INK COST TO STRATEGIC INSIGHT In a data-led production environment, ink is more than a consumable: it becomes a measurable indicator of process effi ciency and product quality. Understanding its use enables converters to answer critical business questions: • Which jobs deliver the strongest margins? • How do diff erent substrates aff ect laydown and waste?


• Do consumption trends reveal press underperformance?


• How can environmental impact be reported more confi dently?


By turning raw ink data into actionable insight, printers can benchmark, forecast and continuously refi ne their operations. The result is improved profi tability, leaner inventory and a more sustainable use of materials.


www.convertermag.com


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