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Web offset press field guide

This reference documents every field you will edit on a press record under Estimate Setup → Print Machines → Web Offset in GelatoConnect Estimator (heatset and…

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Written by Styrbjörn Holmberg

Scope

This reference documents every field you will edit on a press record under Estimate Setup → Print Machines → Web Offset in GelatoConnect Estimator (heatset and coldset continuous-web litho lines). Sheet-fed offset, digital, and large-format presses have their own field guides. Folding and stitching equipment configured on the line are documented under finishing equipment.

Identification

Field

What it controls

When to change this

What depends on it

Name

Display name on the Print Machines list, on quote route information, and in Excluded machines.

When the press is renamed or the label is wrong.

The press name on every quote breakdown.

Manufacturer

Free-text label.

When you transfer the record or fix a typo.

Display only.

Machine Type

Locked at Web Offset. Changing rewrites the editor and drops the cutoff and web-width fields.

Only when first creating the record.

Every cost calculation.

Status

Active or Inactive.

When the press is taken out of service or returned.

Routing.

Tags

Compatibility labels for substrates, finishing, and product categories.

When you onboard or retire a substrate group, ink set, or finishing path.

Routing: missing tag → press excluded.

Web geometry

Field

What it controls

When to change this

What depends on it

Web Width

The roll width loaded on the press, in millimetres.

When you load a different roll width (a planned changeover) or commission a new feeder.

The imposition the planning engine produces: signatures wider than the web are excluded from this press.

Cutoff Length

The fixed signature length the folder produces at every cylinder revolution.

Only when the cylinder dressing changes — cutoff is a mechanical fixture of the press cylinder.

The imposition: the planning engine matches each job's signature length to the cutoff. Quotes whose signature does not divide cleanly into the cutoff are excluded.

Maximum / minimum finished size (width / height)

Min and max finished-piece dimensions the press can produce after fold and trim.

When you change cylinder dressing, fold rollers, or trim setup.

Routing for every quote: pieces outside the range are excluded.

Maximum stock caliper

Thickest paper the press can run through the towers and folder.

When run experience or commissioning differs from spec.

Routing for board and cover jobs.

Operational speeds and labour

Field

What it controls

When to change this

What depends on it

Make-ready hours

Fixed overhead time before the run starts (thread the web, mount plates, register).

When measured make-ready differs from default by ≥0.1 hour.

The Make-ready line on every quote.

Make-ready material cost

Fixed cost added to the paper bucket to cover the web consumed during threading and registration.

When paper or chemistry cost changes.

The make-ready material line on every quote.

Output per hour

Maximum sustained production speed, in impressions per hour.

When commissioning shows a different speed.

The Run-time line on every quote.

Machine rate per hour

Hourly machine running cost.

When you re-cost the press.

The machine portion of make-ready and run lines.

Labour rate per hour

Hourly operator cost.

When operator wages change.

The labour portion of make-ready and run lines.

Paper waste

Web length (or sheet equivalent) added to the substrate quantity to cover web breaks and registration loss.

When run experience shows a different waste profile.

The substrate quantity on every quote. Often higher than sheet-fed because the web must be threaded.

Running spoils %

Additional spoils as a percentage of necessary quantity.

When run experience differs from default.

The substrate quantity.

Offset cost fields (also documented in the sheet-fed offset guide)

Field

What it controls

When to change this

What depends on it

Plate cost

All-in cost of one plate.

When the plate supplier price changes.

The fixed-cost portion of every offset run. Plate count = colours × parts × surfaces.

Plate-making labour per hour

Hourly cost of plate-mounting operator.

When prepress wages change.

The plate-making line on every quote.

Processor plates per minute

Throughput of the plate processor.

When you replace the processor.

The plate-making labour minutes.

Spot-colour make-ready fixed

Fixed labour cost per spot colour beyond CMYK.

When the wash-up procedure changes.

The make-ready labour line on quotes with spot inks.

Paper-coat extra price

Per-coating adder applied to the paper bucket.

When press behaviour on a coating changes or you onboard a new coating.

The paper cost line, scaled by the configured coating amount.

Color units

Number of ink units on the line.

When you add or remove a tower.

The maximum number of colours imageable in one pass.

Impose files price

Per-file imposition charge.

When prepress workflow cost changes.

The prepress line.

Preflight check price per page

Per-page preflight cost.

When preflight tooling or contract changes.

The prepress line.

Pages and imposition

Field

What it controls

When to change this

What depends on it

Pages per impression

Number of finished pages produced per cylinder revolution.

When cylinder dressing changes (different signature layout).

Routing: only quotes whose page count matches the imposition mode use this record. Shops typically configure multiple records per press, one per imposition.

Included steps

Steps the press performs in-line (e.g., print, fold).

When you add or remove an in-line module on the press.

The price breakdown: included steps do not generate a separate finishing line because they are bundled into the press cost.

Things to know

  • A single web offset press is often configured as multiple records, one per imposition mode. A 32-page signature setup and a 16-page signature setup of the same physical press are separate records with different Pages per impression and Maximum/minimum finished size values.

  • Cutoff Length is mechanically fixed by the press cylinder and rarely changes. Treat changes as a re-create rather than an in-place edit.

  • Make-ready material cost is typically higher than sheet-fed because the operator threads metres of web before registration locks. Measure once at commissioning and re-measure annually.

  • Setting click rates on a web offset record has no effect; the click fields belong to digital presses.

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