Start up waste is a familiar problem on most printing presses. At the beginning of a run, operators spend time in job set-up to bring colours into register manually. Until registration stabilises, a significant amount of substrate ends up as waste. This is where an automatic register controller steps in to quickly register colours resulting in a quick job set-up.
How a register controller reduces start up waste
A register controller adjusts colour to colour alignment by detecting register marks and correcting deviations in real time. Fewer metres of substrate are printed “out of tolerance”, which reduces “make ready waste”. The press reaches target speed faster, without operators having to slow down repeatedly, to correct register errors.
Consistency is another key factor. Every job set-up follows the same controlled process, regardless of operator experience/skill. This prevents unnecessary waste from creeping into daily production.
Why this is important for production staff
For operators and production teams, reduced start up waste means less firefighting. Instead of constantly adjusting register and reacting to drifting colours, operators can focus on running the press smoothly.
Lower stress levels, clearer responsibility, and fewer quality complaints improve confidence on the shop floor. It also shortens job changeovers, helping teams meet tight schedules without compromising quality.
Why should we care
Taking a bird’s eye view, start up waste is not just material loss. It affects cost per job, delivery timelines, energy consumption, and customer satisfaction.
By reducing waste at the job set-up, a register controller delivers measurable financial benefits – lower rejection rates, better asset utilisation, and higher throughput – improving margins and operational efficiency.
In short, a register controller turns start up from a waste heavy phase into a controlled, efficient process.
