In wide-format printing, every minute and every meter of material counts. Whether you’re running a single printer or a full production floor, inefficiencies in setup, workflow, or material use can quickly erode profits. At Frontline, we work closely with print providers across North America — and we’ve seen how small process improvements can make a big difference in both output and cost savings.
Here are five proven ways to make your print room more efficient and profitable.
- Standardize and Streamline Your Workflow
In many shops, every operator does things slightly differently — which can create confusion, rework, and lost time.
Establish a consistent workflow for each print type and media category:
- Create step-by-step job sheets outlining printer settings, RIP profiles, and finishing instructions.
- Use pre-set profiles in your RIP software to ensure consistent color and ink usage.
- Assign a lead operator responsible for approving first prints to minimize trial-and-error waste.
When everyone follows the same playbook, you’ll reduce downtime and deliver more consistent results.
- Store and Handle Media the Right Way
Wasted media often comes down to storage and handling errors. Rolls that absorb moisture, become dusty, or develop edge damage can ruin an otherwise smooth print run.
A few simple habits make a big impact:
- Store rolls carefully to prevent core damage.
- Keep your print room at a stable temperature and humidity to avoid curling or adhesion issues.
- Always label media by type, width, and lot number so partial rolls get used efficiently.
Consider Galaxy media storage and handing equipment for optimal performance.
- Match the Right Media to the Right Job
Not all films and fabrics are created equal. Using a high-end cast vinyl for a short-term promotion or an indoor job wastes money and can cause unnecessary reprints if removal becomes difficult.
Before loading the printer:
- Ask where the graphic will be installed (indoor/outdoor, flat/curved surface).
- Consider expected lifespan and removal requirements.
- Consult with your suppliers for best materials for each project.
Better material choices up front save both time and waste downstream.
- Calibrate and Maintain Your Equipment Regularly
A well-tuned printer is an efficient printer. Regular maintenance minimizes unexpected downtime, color drift, and costly reprints.
Set a recurring schedule for:
- Nozzle checks and head cleanings
- Media feed calibration to prevent banding
- Software updates for RIP and firmware
- Cutter alignment for accurate finishing
Keep a quick-reference log so operators can track when maintenance was last done — it’s a simple tool that keeps your production line reliable and predictable.
- Analyze and Optimize Material Usage
Tracking waste is the first step to reducing it.
Encourage operators to record offcuts, misprints, and setup sheets. Over a few weeks, you’ll start to see patterns — maybe a specific media causes feeding issues, or a certain job type always requires test prints.
With that data, you can:
- Adjust panel layout or nesting to get better material yield.
- Train staff on high-waste areas.
- Explore more efficient roll widths or laminate pairings.
Even small changes — a few inches saved per job — add up to substantial annual savings.
Final Thoughts
Efficiency isn’t about cutting corners; it’s about working smarter.
From storage and workflow to calibration and material choice, every process in your print room offers an opportunity to save time, reduce waste, and boost margins.
At Frontline, our Galaxy brand of print media, media storage & handling equipment, and finishing tools and supplies keeps print production safe, streamlined, and efficient.