Labels: Flexo and Digital
Overview
- This model generates a Specification tab where the Label specification can be updated.
- The Inputs, in turn, update the Costings.
- You can add items directly to the Costings using the Input tab.
- The price can appear on the Quote Letter as Unit Price / Label, Price/1000 Labels or Price per Roll – the latter option is rounded, so use it only as an indicative price.
- In most cases, the Tooling (Dies and Stereos) are excluded from the Label Estimate and quoted as separate line items on the Quotation.
Cylinders
Only one Material Category must be linked to the Flexo Cylinders Data Type.
- Add a Material Category and set the Data Type to Flexo Cylinders.
- 1/8 CP and 32 DP modules are supported.
- The Repeat Length (Cylinder Circumference) is calculated according to the module and the number of teeth.
- The Material Category setup has actions to create all the standard 32DP and 1/8CP Cylinders.
Cylinder Lookup
The Cylinder lookup adjusts the Qty Around to match the Gaps filter.
The following fields are situated in the header of the Cylinder lookup and are assigned to the Die when the Cylinder is selected:
- Qty Across
- Gap Across
The following columns are situated in the Cylinder Lookup grid view (visible only when a Die is added/updated from an estimate):
| Field | Description |
|---|---|
| Run Length (m) | Based on the selected Qty on the estimate. |
| Die Width (mm) | Calculated from the Qty Across and Gap Across. |
| Plate Area (sq.cm) | Calculated from the Die Width and the Cylinder Length. |
Dies
Only one Material Category must be linked to the Flexo Dies Data Type.
- Add a Material Category and set the Data Type to Flexo Dies.
- Dies can be added directly in the Materials module, or by navigating to Setup > Products > Menu > Edit Label Dies.
- Dies can also be added from within an estimate.
- Deleting Dies is only possible in the Materials module.
Label Die Setup
- The Machine lookup is positioned in the Cylinder table. When a Cylinder is selected on a Die, the Machine links are copied to the Die.
- When selecting a Cylinder, the default Gap (Around) filter is from 3-6 mm to 2-20 mm. This filter provides a wider range of Cylinder options by default.
- When a Die is Flat or Semi-Rotary, the Cylinder can be cleared and the Gap and Qty Around can be overridden.
- Cylinder lookup: The Die Width and Plate Area are visible even when you are not adding a Die from an estimate.
Important Fields
| Field | Description |
|---|---|
| Shape | The dimension fields that appear depend on the selected Shape. |
| Cylinder | The Cylinder lookup provides functionality to select DP or CP and to rotate the label. The selection shows the Qty and Gap Across for each item. By default, only the Cylinders that give a gap between 3 and 6 mm appear. |
| Material | Links the Die to a Material type – see below. |
| Machine/s | Links the Die to one or more machines (Cost Centres). When the selection is blank, the Die can be used with any machine. The Printing Service is filtered to only show Costings that contain the linked Cost Centres. |
| Image | The Die Pattern is automatically generated for standard label shapes. When Override Image is checked, you can upload a different image. |
| Cost | Edit the supplier and Unit Price of the Die – the price is updated to the Costings tab of the linked material. |
| Gap Around | This value is calculated based on the circumference of the selected Cylinder. The Override function can be used on Rotary and Flexible Dies when the calculated value differs slightly from the gap on an existing Die. The Override does not affect the Die size, however.
|
Warnings
The following warnings appear in a red band:
- Duplicate Code
- Die Width > Cylinder Width
- Label Depth > Cylinder Circumference
Settings
The defaults are the values for new databases and new users. Your database may have different values.
| Setting | Description | Default |
|---|---|---|
| Label Printing - Default - Label Gap Across (Default = 3) | This setting is assigned when a new Die is created. | 3 |
| Default - Substrate margin added to die width (mm/side) | (Default = 5 mm): This margin is added twice (for both sides) to the Die width when calculating the paper width for substrates that are loaded with a unit of sq.m. | 5 |
| Label Printing > Material Category used for Substrates | Identifies the Material Category used for label substrates. Required for the Material Type lookup in the Dies setup. | None |
| Default - Substrate margin added to die width (mm/side) | is applied when Dies are created/updated (applies to Labels (Flexo) and Labels (Digital)). | 5 |
Substrates
If the Subcategory field on a substrate is blank, it can be used with any Die and vice versa.
- Dies are made to work with specific Substrates. It is, therefore, important to link each substrate to a material which is done using the Subcategory field in Materials.
- The Material field in the Die setup lets you select from the list of Materials (Subcategories) of the Substrate Material Category which is identified using the Setting below. The Material field is available in the Die list, hidden by default.
Costing Setup
Recommended Qty Types
- Substrate (Reel) – Part (WS Length m): Used to make the standard Reel widths available when estimating.
- Substrates (sq.m) – Part (WS Area sq.m): Used when you do not have a suitable reel width in stock.
- Printing (Service) – Part (WS Length m)
- Printing (Ink) – Part (Area sq.m): Excludes the gaps between the labels.
Label substrates are generally purchased in jumbo reels (1 000 mm width). They can be slit down to any width based on the quantity to be produced, the width of an existing die and the maximum width of the printing machine.
Waste % – Do not add any Overrides in for the Substrate Costings.
Create Printing Costings as follows:
- Service – the printing service. The Fixed Hr/s = Make-ready time and the Qty/hour = Run Speed in m/hr. The Qty = Part (WS Length m).
- Mat – Add a Material (Ink) item, with a unit of kg or g, for each colour. Fixed Qty = setup/washup waste. The Unit Qty = Ink usage in kg / sq.m at the average coverage. The Qty = Part (Area sq.m).
Product Setup
The Input column in the Printing and Finishing Views provides the functionality to create the lookup lists on the Input tab. If a lookup list is empty, the field is not displayed on the Input tab.
Printing Inputs
The Costings for Plate Changes and Colour Changes must be linked to the same Cost Centre as the Printing Costing.
If all of the above lookups are empty, the Printing Part is hidden.
- Printing – The Printing Service – add options that include/exclude Plates
- Variable Data
- Foiling
- Plate Changes: The Printed column defaults to Setup only
- Colour Changes: The Printed column defaults to Setup only
Finishing Inputs
- Die Cutting
- Embossing
- Lamination
Substrate Waste
- The Substrate Waste is managed by Printing and Finishing Services at a product level.
- The Setup and Run Waste of all the Services that are added to the estimate are summed together.
- You can assign a Setup Waste and Run Waste to the printing-related services (Printing, Colour Changes and Plate Changes) in the Product Estimate setup and in the estimate.
- Setup Waste (m): Enter the metres of waste required for the Service.
- Run Waste %: Is applied to the Nett Qty.
The Setup Waste and Run Waste of the printing-related services are added as follows:
| Service | Setup Waste (m) | Run Waste % |
|---|---|---|
| Printing | Added once. | Added once. |
| Colour Changes | Added once for each colour change. | Added once if the number of colour changes is greater than 0. |
| Plate Changes | Added once for each plate change. | Added once if the number of plate changes is greater than 0. |
| Finishing services | Added once for each unit of the service's quantity. | Added once if the service's quantity is greater than 0. |
The Waste % appears in a separate column. Fixed Width substrates now appear if the width is up to 3 mm less than the die width.
Estimate
| Field | Description |
|---|---|
| Die | Select a die or create a new Die. |
| Charge | The Die is added to the estimate as a material by default; when Charge is unchecked, the Cost of the Die is cleared. |
| Substrate | Select from Reels with a fixed width or from Reels (sq.m) where you can override the width. |
Labels (Flexo) - Estimating Enhancements
- The Die lookup only shows Rotary and Flexible Dies. The Die determines the plate size, regardless of die cutting inline or offline.
- Use the Finishing > Die Cutting option to specify an offline Die Cutting Process. When selected, you can select a different Die (Flat and Semi-rotary) for the offline Die cutting process.
- A section for Tooling Charges is available for Die - Offline or Inline depending on selection. (Previously there was a Charge checkbox.)
- The Die lookup shows the Die Width.
- Foiling: The foil size now defaults to the Die Size.
Printing
| Field | Description |
|---|---|
| Colours | Select a Printing service. |
| Plate Changes | Select from Services linked to the Printing Cost Centre (selected in Colours field). |
| Colour Changes | Select from Services linked to the Printing Cost Centre (selected in Colours field). |
Substrate Summary
When the Colours (Printing Service) selection is changed, the Plate and Colour Changes are cleared.
A Substrate Summary appears at the bottom of the Specification. The Setup Waste and Run Waste are summed from the Printing and Finishing Services (see Substrate Waste) – these values can be adjusted in the Input tab. Fields include:
- Setup Waste (m)
- Nett (m)
- Run Waste (m) and (%): Metres are calculated from the %
- Total (m): Setup Waste + Nett + Run Waste
Warnings
- Die Qty Across is not divisible by Rewind Qty Across.
- Stock Waste > 20%.
- The Material type of the Substrate does not match the Material type linked to the Die.
Worksheet size: The Worksheet size defaults to the Die size when a Paper (sq.m) is selected. An option is available to override the stock width.
When a Reel paper (fixed width) is selected, the Worksheet size defaults to Die Depth x Reel Width.
Plate Costs: Platemaking must be included in the Printing Costing (you must add Costings for each colour option, with and without plates).
Labels (Digital) - New Product Estimating Type
A Product Type is available for Labels (Digital) which works as follows:
- Groups used: Substrate, Printing, Finishing, Materials, Packaging.
- Qty Types used in Costings are the same as used in Labels (Flexo).
- Options (set in the Input tab on the Product Setup):
- Printing: Printing, Foiling
- Finishing: Laminating, Embossing, Varnishing, Die-cutting, Rewinding
- Materials: Cores
Labels (Digital) - Estimating
Similar to Labels (Flexo) with the following changes:
- Die – Can select from all your Dies – The Work size for printing is calculated from the Die, which is assumed to be the Die used for Die-cutting.
- Substrate: Reels are limited to widths that are greater than Work width.
- Printing - Colours: There are no options for Variable Data, Plate Changes and Colour changes.
- Die Cutting: It is assumed Die Cutting is offline and uses the Die selected above.
- Warnings: Same as Flexo Dies.
Output
For the data available on output templates, see Output Data Pipelines.