The amount of ink used in label printing largely depends on the size of the image and text area, which is typically designed by the customer. However, label printing companies have the flexibility to adjust the layout slightly, allowing for some cost-saving opportunities. This requires a bit of "nail" spirit—meaning attention to detail and efficiency—to reduce waste without compromising quality.
1. Understand the difference between two-layer and one-layer ink printing
When printing large areas, many label printers use a two-layer ink system to prevent issues like smudging or dirty spots. But there's another key benefit: using two thin layers of ink can actually use less ink than one thick layer while maintaining the same color density. For example, a job requiring 500 lines per inch with a 4.0 BCM anilox roller to print a special red might instead use a two-layer approach. The first layer could be printed with a 1000 lines per inch, 1.5 BCM anilox roller, followed by a second layer using an 800 lines per inch, 2.2 BCM roller. Visually, the results are nearly identical, and the measured color values meet specifications. However, when printing with a single thick layer, the ink may not spread evenly, leading to a less vibrant look and potential blooming. On coated paper, this issue is even more pronounced. By printing two layers, the first layer helps fill surface imperfections, and the second layer produces a smoother, more consistent finish with better color density.
2. Decide whether polishing is necessary
Polishing (or varnishing) serves two main purposes: enhancing gloss and protecting the label from wear. If the goal is just to increase shine, flexo inks often provide sufficient brightness, making polishing unnecessary. However, if the label is likely to experience friction during transport or use, polishing becomes more important. Some labels, especially those in non-contact areas, may not require any polish at all. Unfortunately, many printers default to polishing without considering the actual need, leading to unnecessary varnish usage. While varnish is cheaper than regular ink, it’s often applied in full-coverage coats, which can result in significant waste.
To avoid this, it’s essential to plan carefully from the start. Ask whether polishing is truly needed, and consider partial glazing for special-shaped labels. If the label will be placed in a non-abrasive area, leaving it unglazed can save costs. For labels that require durability, ensure the varnish layer is thick enough and consider adding anti-wear additives if necessary. The goal should always be to meet the customer’s needs without over-engineering the process. Extra steps lead to wasted resources and higher costs. Keep it simple, efficient, and focused on real value.
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