Compare packaging printing economics: measurements, worked example and comparison

Define the job and measurement boundary

Request separately identified print-form ownership, fixed setup, variable charges, accepted-output quantity and quote validity for both offers.

Allocate entered print-form and setup charges to one explicitly defined job. Reused plates need an evidenced allocation policy rather than assumed future runs.

Work through the numbers

Method A: EUR 100 fixed and EUR 0.08/good pack. Method B: EUR 800 fixed and EUR 0.03/good pack. At 14,000 packs their totals both equal EUR 1,220.

One-time print allocation = (Forms + Setup) / Good printed packs EUR 600 forms plus EUR 200 setup over 10,000 packs = EUR 0.08/pack.

Run cost = Fixed charge + Good packs / Yield × Gross-pack print rate EUR 800 + 10,000 / 0.95 × EUR 0.02 = EUR 1,010.526.

Crossing quantity = (Fixed B − Fixed A) / (Variable A − Variable B) EUR 100 + EUR 0.08/q and EUR 800 + EUR 0.03/q cross at 14,000 good packs.

Avoid the comparison error

A per-good-pack quote already includes the supplier yield allowance. Applying gross-input loss again makes the comparison unfair.

• Entered charges only; ownership and reuse terms remain separate.
• Exclude charges already included in the unit quote.
• Variable quote must be per gross processed pack.
• If quote is already per accepted pack, do not apply loss again.
• Constant unit rates; quantity tiers require separate scenarios.
• Equivalent artwork, finish, substrate and accepted quality required.

Prepare a comparable purchasing decision

Replace each example with dated measurements and confirmed charges for the same SKU and job. Keep unresolved specification differences visible rather than ranking incompatible offers.

Record the original quote unit, material scope, fixed charges, freight and valid quantity tier. Review an alternative as a separate scenario before adding it to the complete packaging cost.

Case: print methods change order advantage with quantity

For A at EUR 100 fixed and EUR 0.08/good pack versus B at EUR 800 fixed and EUR 0.03/good pack, 10,000 packs costs EUR 900 versus EUR 1,100. At 20,000 packs costs become EUR 1,700 versus EUR 1,400.

Both constant-rate scenarios cross at 14,000 packs. Real quantity tiers, substrate, finishing and accepted quality can change the comparison. Retain the original supplier scope and inspect the sensitivity panel for the intended run.

Common questions