Pouch & Production Calculators
Translate a production web into finished packs, order requirements and process waste.
Packs per Roll
Calculate theoretical and waste-adjusted finished packs from roll length, pack repeat and the number of lanes.
Packs per kg
Calculate nominal pack yield per kilogram from the production web layout and film GSM.
kg per 1,000 Packs
Convert film geometry and GSM into kilograms required for one thousand good packs, with optional process waste.
Pouch Weight
Calculate film mass per pouch from its production web, or estimate a simple flat pouch from front and back dimensions.
Material Required for Order
Plan gross film length, area and weight for a target quantity of good packs, allowing for process waste on gross input.
Waste-Adjusted Film Requirement
Calculate gross input required to deliver a net film quantity when waste is a percentage of gross material consumed.
Packaging Scrap Cost
Measure the material cost of process scrap and deduct an optional scrap recovery value to find net loss.
Units per Linear Meter
Convert pack repeat and lane count into units per running meter and meters per standard production quantities.
Printing Plate Cost per Unit
Allocate entered print-form and setup charges to one explicitly defined job. Reused plates need an evidenced allocation policy rather than assumed future runs.
Packaging Print Run Cost
Build a print-conversion budget from fixed charges and a rate billed on gross processed packs. Substrate and other finishing are outside the entered boundary.
Digital versus Flexo Print Break-even
Find the positive continuous cost crossing for two entered printing offers with equivalent good-output scope. Names do not determine which method is cheaper.
Before you start
Use the finished pack dimensions together with the actual web width, repeat and lane layout. Distinguish gross-input waste from an allowance added to the good output requirement.
Inputs to have ready
The exact inputs depend on the selected tool. Common inputs in this section include:
- Roll length
- Print / pack repeat
- Lanes across the web
- Process waste
- Web width
- Film GSM