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 be displayed on the Quote Letter as Unit Price / Label, Price/1000 Labels or Price per Roll - the latter option is rounded, so it should be used as an indicative price only.

• 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.

• Actions have been added to the Material Category setup to create all the standard 32DP and 1/8CPCylinders.

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):

• 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 Flexo 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 3-6mm to 2-20mm. This 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

• Shape: The dimension fields will be displayed according to the selected Shape.

• Cylinder: The Cylinder lookup provides functionality to select DP or CP and to Rotate the label. The Qty and Gap Across are displayed for each Item in the selection. By default, only the Cylinders that would result in a Gap between 3 and 6mm are displayed.

• Material: Links the Die to a Material type - see below.

• Machine/s: Links the Die to one or more machine/s (Cost Centre/s). 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 Centre/s.

• Image: The Die Pattern is automatically generated for standard label shapes. When Override Image is checked, you're able to 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 Item.

• 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 will not affect the Die size, however. Note: The Qty Around and the Gap Around are editable by default on Semi-rotary and Flat dies.

Warnings

The following warnings are displayed in a red band:

• Duplicate Code

• Die Width > Cylinder Width

• Label Depth > Cylinder Circumference

Settings

• Label Printing - Default - Label Gap Across (Default = 3): This setting is assigned when a new Die is created.

• Default - Paper margin added to die width (mm) (Default = 5mm): 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 sqm.

• 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.

• Default - Substrate margin added to the Die Width (mm/side) is applied when Dies are created/updated (Applies to Labels (Flexo) and Labels (Digital)).

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 allows you to 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 (sqm) - Part (WS Area sqm): Used when you do not have a suitable reel width in stock.

• Printing (Service) - Part (WS Length m)

• Printing (Ink) - Part (Area sqm): Excludes the gaps between the labels

Label substrates are generally purchased in jumbo reels (1,000mm width) and 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 % - Don't add any Overrides in for the Substrate Costings.

Printing Costings need to be created as follows:

• Service - This is 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 - A Material (Ink) item, with a unit of kg or g, needs to be added for each colour. Fixed Qty = setup/washup waste. The Unit Qty = Ink usage in kg / sqm at the average coverage. The Qty = Part (Area sqm).

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 will be summed together.

• Setup Waste (m): Enter the meters of waste required for the Service

• Run Waste %: Will be applied to the Nett Qty

The Waste % is displayed in a separate column. Fixed Width substrates are now displayed if the width is up to 3mm less than the die width.

Estimate

• 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 are able to override the width.

Labels (Flexo) - Estimating Enhancements

• The Die lookup has been filtered to only show Rotary and Flexible Dies which is used to determine the plate size, regardless of die cutting inline or offline.

• The Finishing > Die Cutting option is used to specify an offline Die Cutting Process. When selected, you are able to select a different Die (Flat and Semi-rotary) for the offline Die cutting process.

• A section for Tooling Charges has been added for Die - Offline or Inline depending on selection. (Previously there was a Charge checkbox.)

• The Die Width has been added to the Die lookup.

• Foiling: The foil size will now default to the Die Size.

Printing

• 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 will be cleared.

A Substrate Summary is displayed at the bottom of the Specification. The Setup Waste and Run Waste are summed from the Printing and Finishing Services - these values can be adjusted in the Input tab. Fields include:

• Setup Waste (m)

• Nett (m)

• Run Waste (m) and (%): Meters 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 (i.e. you need to add Costings for each colour option, with and without plates).

Labels (Digital) - New Product Estimating Type

A Product Type has been added 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 Die is used to calculate the Work size for printing and 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

The following Data Pipelines can be used for Label Printing.

Quotations

• QT_Item_Image_Rewind - The Rewinding direction image

• QT_Item_Image_Impo - The Die layout

• QT_Item_Image_Artwork 

• QT_Item_Label_Printing - Contains all the fields from the linked Estimate, Die and Cylinder

• Est_Qty_Price / Est_Qty_Price_No_Active - TOTALROLLUNIT - The Unit Price (excl. VAT) for one roll - this is an indicative price only.

Work Orders

• WO_Label_Image_Rewind - The Rewinding direction image

• WO_Label_Image_Impo - The Die layout

• WO_Label_Image_Artwork

• WO_Label_Image_DieFin

• WO_Label_Printing - Contains all the fields from the linked Estimate, Die and Cylinder