Estimating Ink Coverage


The amount of ink coverage is determined by several differnt factors. Press conditions, anilox volumes, the strength and viscosity of the ink and most importantly, the substrate. The best way to measure mileage from run to run is to chart the actual job. Example: If 100lbs of ink goes out to press, and 20 lbs are returned, it is safe to assume that 80lbs were used. You can divide the 80lbs by the number of labels printed and get your answer. Write this number in the job jacket. If all conditions remain the same

If printing the job for the 1st time, ink can be estimated by the following method:

1.) Determine Anilov Volume. Example: (4.5BCM)
2.) Determine if substrate is Porous or Non Porous.
3.) Determine total square inches of coverage needed for the color.
4.) Determine the pounds needed for set up.
5.) Weight per gallon is usually 9lbs, 10.5 to 11lbs for white


Anilox Volume Porous Non Porous
BCM Coverage Per Pound Coverage Per Pound
2-3 BCM 325,000 sq/in 370,000 sq/in
3-4 BCM 232,000 sq/in 270,000 sq/in
4-5 BCM 155,000 sq/in 180,000 sq/in
5-6 BCM 132,000 aq/im 155,000 sq/in
6-7 BCM 115,000 sq/in 135,000 sq/in


Anilox Volume 5 BCM
Substrate is Coated 1 side, High Gloss Paper (Non Porous). 180,000
Job requires how many inches of coverage? 1,000,000 sq/in
Divide 1,000,000 by 180,000 5.5 lbs
3 lbs for the pan and .5 lbs for set up 3.5
5.5 lbs + 3 lbs + .5 lbs = ( 9 pounds of ink is needed for this job). 9 lbs