Reducing waste and increasing yield in roll-to-roll printing: a case study with global scalability

Abstract Roll-to-roll (R2R) printing suffers substantial substrate material losses during splicing, start-ups, and register stabilization, directly reducing yield and profitability. This study applied a Statistical Process Control (SPC) framework integrated with Define–Measure–Analyze–Improve–Control (DMAIC) methodology to reduce substrate material waste in high-speed printing production. Key interventions include condition-based maintenance of tension-critical components, adoption of thin “all-in-one” metallic splicing tapes, and optimized start-up sequences involving ink feed calibration, camera timing, and make-ready speed adjustments. Statistical analysis confirmed a significant yield increase from 219 to 222 pages/kg, validated through t- tests and control charts. The improvements generated annualized savings of $1.07 million USD per printing plant without increasing variability. Beyond economic gains, the reduced substrate use also lowered energy demand, water consumption, and associated emissions, demonstrating strong sustainability co-benefits. The results highlight SPC-DMAIC as a scalable model for continuous improvement in R2R operations, with direct applicability to package and publication printing, flexible packaging, printed electronics, and other web-based manufacturing processes.