Printing, Labels & Industrial Converting worked example

Matrix Waste at 65% expected die-station uptime: a worked example

This worked example runs the matrix waste numbers for a tougher week than the baseline: 65% expected die-station uptime instead of the typical 90%. Estimate matrix waste for printing, labels and industrial converting using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Matrix skeleton scrapped per die cycle: 4 units / cycle (held at the documented default)
  • Available die-cutting cycles in the run: 480 cycles (held at the documented default)
  • Expected die-station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected matrix-strip first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross matrix waste capacity = matrix waste output per cycle × available matrix waste cycles.
  • Good matrix waste capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross matrix waste capacity works out to 1,920 units at these inputs.
  • Matrix waste downtime loss works out to 672 units at these inputs.
  • Matrix waste yield loss works out to 37.44 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where expected die-station uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • Use it when planning or reviewing die-cut runs to predict net good output and isolate how much is lost to stops versus strip defects. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good matrix waste capacity: 1,211 units (headline result)
  • Gross matrix waste capacity: 1,920 units
  • Matrix waste downtime loss: 672 units
  • Matrix waste yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Matrix Waste calculator, set expected die-station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.