November 2003: Calculating Production Quantities

You’ve just finished planning and designing your next major marketing project. All of the files needed to print it are fully prepared, and print production is set to begin. There’s just one more question you need answered: How many should I produce?

Calculating production quantities is one of the most overlooked details of a print project. It’s also one of the most important - you certainly wouldn’t want to end up short-handed or produce more pieces than you know what to do with! Here are a few important tips to keep in mind during planning to be sure you know exactly how many pieces you’ll need to print:

CALCULATING SPOILAGE
Whether your project is a simple self-mailer or a multi-component marketing piece, it will likely go through several post press production steps prior to completion. Consider the processes required to create even a basic pocket folder: die cutting, stripping, folding and gluing.

To view a complete Spoilage Chart including all the services we offer, click here to download the .pdf file.

To calculate how many pieces you’ll need to print in order to wind up with the desired quantity, you must determine how much spoilage each production process will consume. A spoilage rate chart, such as the one shown above, can be used to quickly calculate how much spoilage each process will require. Note that these spoilage rates are expressed as a percentage of a given quantity.

Keep in mind that spoilage is cumulative. To calculate an accurate production quantity, you will need to determine the spoilage rates from each production process and add them together. Be sure to account for set up sheets in your spoilage equation as well.

Complex projects may require additional spoilage factors - A particularly intricate die cut or complex fold may render “standard” spoilage rates a bit conservative. If that’s the case with your project, we will help you calculate a more realistic production quantity.

THE RIVERSIDE EDGE
Spoilage rates are based on industry averages and vary little between providers. However, a post press services company that can perform a complete range of binding and finishing services under one roof can usually keep spoilage to a minimum by minimizing handling and transportation. These advantages can add up to fairly substantial savings in both time and money as quantities climb.