Roll Media Optimization

Roll media is often the largest ongoing cost in a wide-format print shop. Total Print helps you see how each layout decision affects roll usage so you can reduce waste over time instead of guessing. This page explains how to think about optimization and which numbers to pay attention to.

Choosing the right roll width

The roll width you load into a printer has a huge impact on waste. A layout that is efficient on one width might waste a lot on another. In Total Print, you can experiment with different roll widths and immediately see how the required length changes. When you are unsure which roll to use, run a quick comparison in the calculator before committing.

Avoiding unusable leftovers

Many shops end up with short roll leftovers that are too small for most jobs. Over time these pieces fill the rack and rarely get used. When reviewing layouts in Total Print, pay attention not only to the total length but also to how that length compares with the full roll size you plan to load. Whenever possible, choose layouts that leave a remaining tail long enough to be useful for a future job.

Tracking simple KPIs

You do not need a full analytics system to benefit from optimization. Start with a few simple metrics that you can track in a spreadsheet:

Average roll utilization – estimate what percentage of printed area is sellable work versus offcuts.
Number of leftover rolls – count how many partial rolls remain on the rack at the end of each week or month.
Reprints due to layout issues – track how often poor layouts cause reprints that consume extra media.

Using Total Print as a planning tool

Treat Total Print as a safe place to test scenarios before any media is loaded. Import the jobs you plan to run, adjust quantities and roll widths, and compare layouts that prioritize either lower waste or easier cutting. Over time this habit makes it natural for operators to think about media usage before hitting print.

Example: estimating savings