Work out print roll length instantly with clear inputs, formula shown and shareable results.
The run length is impressions divided by the number across the web, times the cylinder repeat length. Set-up waste for registration, colour matching and reel splices is a fixed length regardless of run size, which is why short runs carry a much higher waste percentage.
Print roll length
Repeats = ceil(impressions / across web); run length = repeats x repeat length; total = run length + set-up waste
Set-up waste and plate or cylinder cost are fixed. On a 500 m run, 250 m of set-up waste is 33% of the roll; on a 20,000 m run it is 1.2%.
Digital printing eliminates most make-ready waste and suits short runs. On conventional presses, pre-register systems and closed-loop colour control cut it by half or more.