You may not notice a gradual increase in ink usage straight
away.
There is rarely one particular day when someone on the
production line says, “This printer is suddenly using far too much ink.” More
often, the signs build up over time. Ink deliveries seem to be happening more
frequently, consumable costs start creeping up, or the printer simply appears
to be using more ink than it used to.
When that happens, it is worth investigating.
Increased ink consumption is not always caused by one major
fault, and replacing the printer is certainly not the first answer. Sometimes
the cause is relatively straightforward. A change in printer settings,
production patterns, maintenance requirements or the application itself could
all affect how much ink is being used.
The important thing is to identify why the consumption
has changed before assuming that the answer is simply to order more ink.
Here are some of the most common reasons an industrial
printer may be using more ink than expected.
Has anything changed on the production line?
This is often the best place to start.
Before looking for a technical fault, consider whether
anything has changed in the way the line is operating.
For example:
- Has
production increased?
- Are
you running for longer hours?
- Has
the line speed changed?
- Are
more products being coded?
- Have
you introduced new packaging or additional SKUs?
- Has
the amount of information being printed increased?
If you are producing more products, it is only natural that
ink consumption may increase as well.
However, the relationship is not always quite that
straightforward. If production levels have remained broadly the same but ink
consumption has noticeably increased, there is likely to be another factor
involved.
A simple comparison between previous and current production
volumes can be useful. Looking at ink consumption in relation to the number of
products produced may give you a clearer picture than simply looking at how
many ink bottles have been ordered.
The code itself may be using more ink
It is easy to focus on the printer when the actual issue is
the coding requirement.
Have you changed what is being printed?
A larger code, additional lines of information, a different
font, more characters or changes to print settings can all affect ink usage.
For food manufacturers, coding requirements can change for a
number of reasons. New products may require additional batch information,
customer specifications may be different, or packaging may need more detailed
product identification.
Even relatively small changes can add up when thousands of
products are passing through a production line.
If your printer has recently been reprogrammed or new
products have been introduced, it is worth checking whether the coding
requirements themselves are responsible for the increased consumption.
Are the printer settings still right for the application?
Industrial printers are often set up correctly when they are
installed and then left largely untouched.
The problem is that production lines do not always stay the
same.
Changes to packaging, substrates, line speeds and code
requirements can all mean that settings which were once appropriate are no
longer the most efficient.
Depending on the printer and application, settings relating
to print quality and code appearance may influence ink consumption. Using more
ink than necessary does not always improve the quality of the code.
In fact, using the wrong settings can sometimes create the
opposite problem, resulting in codes that are less consistent or more difficult
to read.
The aim should always be to achieve a clear, reliable code
that is appropriate for the application, without using more consumable than
necessary.
This is why reviewing printer settings should be part of the
investigation when ink usage starts increasing.
Has the packaging material changed?
Different substrates can behave very differently when it
comes to industrial coding.
A printer that performs efficiently on one material may need
different settings or a different ink when the packaging changes.
Food manufacturers frequently work with a wide range of
materials, including:
- Plastic
packaging
- Flexible
films
- PET
- Glass
- Corrugated
cardboard
- Aluminium
cans
- Shrink
wrap
A change in substrate can affect how well the ink adheres
and how the code appears.
If the printer is using more ink because settings have been
adjusted to compensate for a packaging change, it may be worth reviewing
whether the current ink and coding solution are the best combination for the
application.
Using the correct ink for the substrate is important for
more than just controlling consumption. It can also help achieve the required
adhesion, durability and code quality.
Is the printer being properly maintained?
A gradual increase in consumable usage can sometimes be an
early sign that a printer needs attention.
Industrial printers work in demanding environments. Dust,
production residues and other environmental factors can all affect performance
over time.
If maintenance is delayed or the printer is not operating as
efficiently as it should, this may contribute to increased consumption or other
performance issues.
That does not mean every increase in ink usage points to a
serious problem. But it is worth considering whether the printer is due for a
service or whether there are signs that something is not operating as it
should.
Regular maintenance is not just about preventing breakdowns.
It can also help identify smaller issues before they become more expensive
problems.
Is the printer running when it does not need to be?
Production patterns can also have an impact on overall
consumable use.
Long periods of operation, changes in shift patterns or
unexpected downtime can all affect how the equipment is being used.
For example, a printer may be operating for extended periods
while little or no product is being coded. Depending on the technology and
application, this may contribute to unnecessary consumable use.
It is worth looking at how the printer is actually being
used during a normal production day.
Are there periods when the line is stopped but the printer
continues to run? Have production schedules changed? Are there frequent stops
and starts?
Understanding the difference between production time and
actual operating time can sometimes reveal opportunities to reduce unnecessary
usage.
Are operators making frequent adjustments?
When a printer starts requiring regular attention from
operators, it is often a sign that something should be investigated.
Perhaps the code position is being adjusted frequently.
Maybe settings are being changed between products, or operators are trying to
compensate for inconsistent code quality.
These adjustments can sometimes lead to inefficient printer
operation, particularly when settings are changed without a clear understanding
of how they affect the application.
This is not about blaming operators. Production teams need
to keep the line moving, and they will naturally make adjustments to resolve
immediate issues.
However, if the same adjustments are being made repeatedly,
there may be an underlying cause that needs to be addressed.
A review of the printer setup, the application and operator
training may help identify a better long-term solution.
Are you comparing like with like?
One of the challenges when investigating ink usage is that
businesses often compare current consumption with a previous period without
considering everything that has changed.
For example, if production has increased by 20%, it would be
reasonable to expect some increase in consumable use.
A better approach is to look at the amount of ink being used
against actual production output.
You could compare:
- Ink
used per shift
- Ink
used per production run
- Ink
used per number of products coded
- Ink
consumption for different products or packaging types
This can help identify whether the increase is genuinely
unusual or simply reflects changes in production.
It can also highlight where a particular product, line or
application is using significantly more ink than expected.
Small increases can become significant costs
A small increase in ink consumption may not seem
particularly important at first.
But when a production line is running day after day, week
after week, small amounts of additional ink can quickly become a significant
cost.
The same is true of the time spent by operators dealing with
printers that are not performing as efficiently as they should.
That is why it makes sense to investigate changes early.
The goal is not necessarily to use the least possible amount
of ink. The priority must always be a clear, reliable and compliant code.
But once that has been achieved, there is no benefit in
using more consumable than the application requires.
Don't simply treat increased ink use as the cost of
production
If your industrial printer is using more ink than usual,
there is usually a reason.
It could be as straightforward as increased production
volumes or changes to the information being printed. Equally, it could indicate
that printer settings need reviewing, maintenance is required or the current
coding setup is no longer the best fit for the application.
Before ordering more consumables or assuming that higher ink
usage is unavoidable, take a step back and look at the bigger picture.
- What has changed?
- When did the increase start?
- Is the printer producing more, or simply using more?
Those questions can often point you in the right direction.
Need help understanding your printer's ink consumption?
At Industrial Printer Services, we work with manufacturers
to help them get the best possible performance from their industrial coding
equipment.
If your ink consumption has increased and you are unsure
why, we can help review the printer, the application and the way it is being
used.
Sometimes the answer may be a straightforward adjustment. In
other cases, the issue may require maintenance, a change in consumables or a
wider review of the coding process.
The important thing is to understand the cause rather than
simply accepting higher ink usage as part of the job.
If your industrial printer is using more ink
than expected, Contact us today and let us help you identify what may be
causing the increase.
