Allowance

In printing technology, allowance refers to the additional quantity of paper required beyond the actual number of printed sheets needed for the final product. This extra material is essential for setting up printing machines, adjusting production parameters, and carrying out finishing processes reliably.

The amount of allowance depends on several production-related factors, including the print run, printing process, printing machine, type of print, number of colors, and the complexity of the finishing work.

More details

When calculating and ordering raw materials for printed products, the necessary allowance for both printing and finishing must be planned in advance. This ensures that enough material is available not only for the final quantity, but also for machine setup, test sheets, adjustments, and unavoidable production-related material losses.

The required allowance is influenced by the specific form of the order, the machines used, and the individual production steps involved. Its purpose is to compensate for material losses that occur during normal print production and post-processing.

Important influencing factors include:

• Requirements during printing, such as the number of print passes and the number of colors
• Requirements during finishing, such as folding steps, binding type, cutting, or other processing stages
• Order-specific requirements, for example particularly complex print layouts or demanding production forms
• Company-specific production factors, such as the age and condition of the printing machines, staff experience, and the handling of setup waste

In general, a distinction is made between fixed allowances and variable allowances.

Fixed allowances are required for setting up the printing machines and are independent of the print run quantity. They include, for example, additional sheets needed to adjust color control, align the printing plates precisely, and bring the individual printing units into the correct position. Only after these setup steps have been completed can the actual production run begin.

Variable allowances, on the other hand, depend on the size of the print run and are usually calculated as a percentage. They compensate for material losses that occur during the actual printing process and during finishing. The larger or more complex the production run, the more carefully these variable allowances must be calculated.

A well-calculated allowance helps ensure smooth production, consistent print quality, and reliable delivery of the required final quantity. If the allowance is calculated too low, there may not be enough usable material to complete the order. If it is calculated too generously, unnecessary additional costs may arise for paper, cardboard, storage, and waste handling.

For this reason, allowance calculation is an important part of professional print planning. It helps balance production reliability, material efficiency, and cost control.