Printing • Lamination • Slitting • Pouching | Capacity in MT | Changeovers derived from Roll Length + Speed
1. Plant Working Parameters
PE ≈ 0.92 | PET ≈ 1.39 | BOPP ≈ 0.91
2. Efficiency & Roll Changeover Logic
How changeovers are calculated now:
Number of Changeovers = Total meters the machine can run ÷ Average Roll Length
Changeover Loss % = (No. of Changeovers × Changeover Time) ÷ Available minutes × 100
This is calculated separately for each machine type using its own speed.
Standard jumbo / finished roll length (commonly 24,000 m)
Time from end of one roll/job to start of next good production
Breakdowns, maintenance, power cuts
Registration, colour, defects, start-up waste
Running below rated speed, operator skill
Overall Efficiency will be calculated after you press Calculate
Changeover loss is now machine-specific (based on its speed + roll length)
3. Printing Machines (Gravure / Flexo)
4. Lamination Machines
5. Slitting Machines
6. Pouching Machines
Note: Pouching changeovers are usually fewer and handled via the Quality + Speed efficiency factors.
Results – Monthly Production Capacity (in MT)
Machine-wise Capacity + Changeover Details
Process
Qty
Speed
Est. Changeovers / Day
Changeover Loss %
Capacity (MT/month)
Logic used:
1. Available minutes per day (after uptime) → theoretical meters = Speed × available minutes
2. Number of Changeovers = Theoretical meters ÷ Roll Length (24,000 m default)
3. Changeover Loss % = (Changeovers × Changeover Time) ÷ Available minutes × 100
4. Final efficiency for that process = Uptime × (1 – Changeover Loss) × (1 – Quality) × Speed Eff
5. Capacity (MT) is then calculated using the process-specific efficiency.
Typical values: Roll length 20,000–30,000 m | Changeover 15–40 min |
Overall efficiency after all losses usually 55–75% in converting plants.