Whether you are running a Flexo or Gravure printing operation, profitability depends on how effectively you control material consumption, wastage, production data, and repeat-job information.

Here are some of the key areas that can make a significant difference:

1. Ink Coverage

Ink consumption should be considered right at the estimation stage.
With the cost of ink per KG/litre increasing significantly, even a small variation in ink coverage can have a considerable impact on the overall job cost.
Your estimation system should consider ink coverage, colour-wise consumption, and the estimated ink requirement before finalising the job cost.

2. Raw Material Planning

Optimised raw material planning is critical.
The job should be planned in such a way that you achieve maximum utilisation while controlling wastage.
At the same time, you need to consider the requirements of all subsequent processes after printing and calculate the expected wastage accordingly.
A good production plan can directly contribute to better margins.

3. BOM & Data Management for Repeat Jobs

Repeat jobs should never be treated as completely new jobs.
All data from previously executed jobs should be preserved so that the same specifications can be reused without confusion.
For Flexo, you should be able to maintain details such as:

• Nylon plate information
• Colour details
• Anilox specifications
• Raw materials used
• Machine/process details
• Other production parameters

Similarly, for Gravure, complete cylinder information, along with raw materials, colours and processes used, should be maintained.
This historical data can significantly improve consistency and reduce dependency on individual people’s memory.

4. Production Data & Wastage

Capturing production data is equally important.
You should maintain:

• Actual material consumption
• Production quantity
• Process-wise time taken
• Process-wise wastage
• Machine performance
• Actual vs. estimated consumption

Most importantly, wastage should be captured at every stage.
Once you have this data, you can analyse why wastage is occurring and take corrective action when a similar job is produced in the future.

One System to Manage It All

With Pezasys ERP, you can manage these activities in one integrated system—
from estimation and BOM to production, inventory, purchase, sales, quality, wastage and reporting.

The objective is not just to digitise your processes, but to help you make better decisions using the data generated from your own production operations.
And based on feedback from our customers and users, Pezasys ERP is designed to be easy to learn, implement and use.

For a flexible packaging business, controlling every KG of material, every minute of production time and every percentage of wastage matters.
That is where the right ERP can make a real difference.