The Hidden Costs of Poor Cylinder Management – And How to Fix It!

Cylinder management is crucial in the printing industry, yet many overlook its importance, leading to significant hidden costs that can impact overall efficiency and profitability. Here’s a breakdown of these hidden costs and how implementing effective management solutions can mitigate them.

1. Increased Press Setup Times

Poor cylinder management often results in longer setup times due to mismatched or poorly maintained cylinders. Each additional minute spent on setup is time lost on production, leading to decreased press availability and increased labour costs.

2. Excessive Waste

Inefficient cylinder management can cause excessive material waste. When cylinders are not in optimal condition, print quality suffers, resulting in more rejected prints and higher waste disposal costs. Properly managing the condition and usage of cylinders helps maintain consistent quality and reduces waste significantly.

3. Higher Maintenance Costs

Without proper monitoring, cylinders can wear out faster, leading to frequent maintenance and replacement needs. Regular maintenance scheduling and accurate condition tracking can extend cylinder life and reduce unexpected downtime and repair costs.

4. Lost Customers and Reduced Customer Loyalty

Inconsistent print quality due to poor cylinder management can lead to dissatisfied customers and a tarnished reputation. Ensuring that cylinders are well-maintained and producing high-quality prints consistently can improve customer satisfaction and loyalty.

5. Increased Inventory Costs

Mismanagement of cylinders can lead to overstocking or understocking, both of which are costly. Overstocking ties up capital in unused inventory, while understocking can cause production delays and missed deadlines. Implementing a robust inventory management system helps balance inventory levels and reduce associated costs.

Solutions for Effective Cylinder Management

To address these hidden costs, consider the following strategies:

  1. Implementing Cylinder Management Systems (CMS)
      • Troika’s CMS can track the condition and usage of each cylinder, providing detailed insights and scheduling maintenance efficiently. This helps in planning refurbishment or replacement, reducing unexpected downtimes.
  2. Regular Maintenance and Calibration
    • Schedule regular maintenance and calibration checks for all cylinders. This ensures they remain in optimal condition, reducing the risk of print quality issues and extending their lifespan. 
  3. Advanced Monitoring Tools
    • Use advanced tools like Troika’s AniCAM HD™ Plus and SurfaceCAM HD™ for precise monitoring and management of cylinders. These tools provide detailed 3D scans and comprehensive data, helping to maintain consistent quality and reduce setup times.

By addressing these hidden costs through effective cylinder management, you can significantly enhance your printing operations, reduce waste, and improve profitability. Investing in the right tools and training can make a substantial difference in your bottom line. For example, saving just one hour of press time per day can lead to an annual saving of approximately €90,000 for a label printer and €150,000 for a wide web printer.

Learn more about Anilox Cleaning Services or contact us for more information.