Why Your Printing Business is Bleeding Money – And How to Stop It...?

With 22+ years in the printing and Packaging industry, we’ve seen thousands of Printers make the same costly mistake: Assuming that I am making money because machines are running.

The truth? 

Most Printing and Packaging businesses leak 20-30% of profits through unmeasured inefficiencies.

[Data-Backed Reality Check]

• 78% of printing and Packaging businesses don’t track Overall Equipment Efficiency.

• Unlogged downtime averages 17% of production time.

• 60% of "busy" Printing and Packaging can’t accurately calculate job costs.

  
  

The Hidden Inefficiencies Destroying Your Profits

Most printing business owners think they understand machine inefficiency. They track major breakdowns and obvious slowdowns.

But the real profit killers? 

The invisible gaps in your production that no one notices—until it’s too late.

1. The Silent Thief: Micro-Downtime

You track major breakdowns but what about the hundreds of tiny pauses draining your productivity every day?

 Shocking Fact:

• An operator waits 8 minutes for approval before starting the next job.

  ○ This happens 4 times a day.

  ○ = 32 minutes lost daily → 16 HOURS per month on ONE machine.

  ○ That’s TWO full shifts vanishing—just from waiting…?

 Fix It:

• Pre-Approval System: Have supervisors review and approve the next job before the current one finishes.

•  Delegate authority: Train leads to approve routine jobs (cuts 80% of waits).

• Visual alerts: Use colored flags to signal "approved/urgent" jobs (reduces check-ins by 50%).

  
  

Result: Save 12+ hours/month—enough to run 30 extra jobs on the same machine.

2. The Cost You Never Calculate: Material Waste

You measure paper and ink usage—but do you track where it’s really going?

 Shocking Fact:

• 12-18% of materials are wasted due to:

  • Setup errors (misaligned cuts, wrong ink mixes)

  • Overruns ("just in case" extra prints)

  • Unlogged test runs

Fix It:

• Setup checklists: Laminate step-by-step guides for each machine (cuts errors by 40%).

• Overrun caps: Track past overruns and adjust planning to reduce unnecessary extras.

• Test log: Operators mark every test sheet, with a limit of three per test, cutting waste by 20% overnight.

  
  

Result: Save Rs.1,50000/month on materials.

3. The Great Lie: "Our Machines Run at 80% Efficiency"

You think your presses are productive most of the day. The data says otherwise.

Shocking Fact:

• True machine utilization is often 50-65% due to:

  • Slow changeovers (taking 2x longer than necessary)

  • Excessive test prints (wasting sheets before "perfect" quality)

  • Unrecorded micro-stops (jams, adjustments, operator breaks)

Fix It:

• Changeover Drills: Track crew swap times and reward the fastest teams—reduces changeover time by 25%.

• Test Print Limits: Enforce a "maximum 3 sheets" rule—saves over 15 sheets per day.

• Downtime Log: Set a team rule: If a machine stops, log the reason before restarting.

  
  

Result: Gain 100+ extra production hours per machine each year.

The Bottom Line: You Can’t Fix What You Don’t Measure

Now choice is your either measure all these things by yourself or You can take our help to stop the constant bleeding of your money…

Remember;

Your competitors aren’t necessarily faster or cheaper, they’re just tracking what you’re ignoring.

Want to know more? Visit - www.printpulse.biz and book a free efficiency audit with our team.