Posts Tagged ‘print industry’


Out of 2, 50,000 printing presses in India, more than three-quarter of them are small-sized printers (SSP) venturing in low value commercial printing segment. These printers are in mystic enterprise world, in which value of their each useful resource is growing, but margins are dwindling thanks to price war in addition to challenges of new technologies and digital economy. It is not a feature Indian print market alone, similar trend is observed globally.

An inclusive and frugal innovation is required to address this complex trivia. It is not about the next big thing, but about making the most of the last big thing. Gandhian Engineering & Indovation will be the key to survival in this complex market.

What is Gandhian Engineering (GE)?

Embracing Mahatma Gandhi’s ideal of “doing More, for Less, for More, (MLM)”, it aims to democratize technology with Affordable Excellence – Giving high quality at affordable prices! It breeds a new kind of innovation coined as Indovation: “Spend less and innovate.”

Optimal utilization of resources & raw materials are key areas to focus in Indovation.

Indovations for small printers segment:

1. 29” Press or 26” Press? Best of both?

Most of Indian/Asian jobs are printed in demy size (19 x 26 inches) or double demy (25 x 36 inches). But for ganging jobs like visiting cards & invitation etc., a 29” press is required. Even though we can a print a 26” (inch) job on a 29” (inch) press, difference in plate size increases cost by more than 5%.

Indovation is to “Change the ink & water forme rollers of the press to 26”(inch) size to use 26”(inch) plate itself thus reducing overall print cost by 3%. When printer requires bigger size (29” inch) to be printed, replacing ink & water forme rollers will suffix. On an average, this increases printer margins by 10% with increased job capability.

Figure 1: By changing roller 12 & 6 to 26", printer can save plate cost

2. Printing trim waste paper with double gripper jobs:

Most B3 presses can run a minimum paper size of 4” (inches) x 6” (inches). When trimming papers for Demy (19 x 26” inches) from 30 x40”inches paper, there will be wastage of 4 x 20”inch. These wastage papers are sold in 30% of paper cost in kilos

By imaging a printing plate with two different jobs like below, in a B3 size press, the customer can print first job in 4×20” for a typical visiting card, invitations imposed for this paper size.

After completing first job, same plate is dismounted and fitted for the second job (gripper edge interchanged). Thus it reduces cost of printing plate for one job and also reduces paper cost by 70%. It is known as “Cutting bits to Commercial Prints”. It increases profitability by 33% in average.

3. Printing in 3 Colors

For a typical commercial printer with a 4 color press, printing 5 color job needs two print passes and hence reduces his competitiveness against printers with 5, 6 color presses. So utilizing the ancient printing technique of converting a CMYK job – CMY using designing software like corel draw will help printer complete the job in one pass. Printing in 3 color means doesn’t compromise the print quality. A very close simulation and quality towards 4 colors can be achieved by proper color management techniques.

This method has been tested and successful in entry level packaging jobs like fireworks boxes and garment jobs. It increases profitability by 16% in average.

Figure 3: A typical garment job, where a 4 color CMYK image will be printed in 3 color CMY combination without compromising print quality


Indovation in commercial print is a true win-win combination of ‘excellence’ and ‘application’ together. It gives printers ‘affordable excellence to thrive on the powerful combination of scarcity and aspiration. Most of the described Indovations has been tested in real market conditions and getting successfully utilized by the printers.