Industrial Packaging Materials Manufacturing worked example

Print Registration Loss at 3.45% target registration waste rate: a worked example

This scenario runs the print registration loss calculation on the strong side: 3.45% target registration waste rate, with every other input held at its documented default. Use this when tracking press waste from registration errors, justifying automatic register control investment, or comparing registration loss across shifts, operators, or press configurations.

The inputs for this scenario

  • Footage lost to misregistration: 800 linear ft (unchanged)
  • Total footage printed: 20,000 linear ft (unchanged)
  • Target registration waste rate: 3.45 % (raised for this scenario; the documented default is 3)

Working through the calculation

  • Applying the documented formula (Registration loss rate = footage lost to misregistration / total footage printed x 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 4 % for registration loss rate, the number this scenario is built around.
  • At this operating point the engine returns -0.55 points for gap to target waste rate.
  • At this operating point the engine returns 800 count for footage lost to misregistration.
  • At this operating point the engine returns 20,000 count for total footage printed.

How this compares with the baseline

  • Against the tool's baseline example, where target registration waste rate sits at 3% and the headline result is 4 %, this scenario lands almost exactly on the baseline at 4 %.
  • Use it after each long run or shift to grade press registration performance and to flag jobs where scrap is running above your accepted threshold. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Registration loss rate: 4 % (headline result)
  • Gap to target waste rate: -0.55 points
  • Footage lost to misregistration: 800 count
  • Total footage printed: 20,000 count

Run it with your numbers

  • Every input above is editable in the live Print Registration Loss calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.