Optimization of Ribbon usage in TTO Printer for Reduction of
Printing cost in Food packaging Industry
1st Prof. Swapnil Choudhary, 2nd Mr. Nikhil Bhondve, 3rd Mr. Sahile Bhusri, 4th Mr. Parmanand
Dubey,5th Sangharsh Yadav
Dept. Of Mechanical Engineering,
Wainganga College of Engg. Management, Nagpur, Maharashtra, India
[email protected], 5th
[email protected] Abstract
This paper presents an optimization strategy of ribbon to reduce printing costs in Thermal Transfer Overprinting (TTO) for
food packaging. This research explores cost-reduction strategies specific to TTO printing by analyzing the impact of
optimized ribbon usage. The study evaluates the printing process for Mini MM’s Biscuit (33g) SKU. Data was collected
from multiple manufacturing facilities to identify key cost drivers and assess the effectiveness of various reduction
methods. The study evaluates the printing process for Mini MM’s Biscuit (33g) SKU. The current practice involves
printing two staggered prints at a 2 mm letter height using a standard 33 mm ribbon width, resulting in significant waste.
The study explores reducing the letter height to 1.75 mm and increasing the coding window height by 5 mm to
accommodate three staggered prints. The findings demonstrate that three staggered prints can be achieved, improving
ribbon utilization by 12%. This improvement has been reduced printing costs from ₹0.25/kg to ₹0.13/kg, with potential
total savings over ₹50.4 lakh a year.
Keywords— Thermal Transfer Overprinting (TTO), Ribbon Optimization, Printing Cost Reduction, Food Packaging,
Staggered Printing, Coding Window, Material Waste Reduction, Print Head, Legal and FSSAI Compliance.
1. Introduction
This research was conducted at Narayana Foods Pvt. Ltd. with the objective of reducing printing costs through the
effective optimization of ribbon usage in Thermal Transfer Overprinting (TTO) for food packaging. Narayana Foods Pvt.
Ltd. is a leading producer of biscuit packaged food products, where TTO printing plays a crucial role in coding essential
information such as batch numbers, expiration dates, and traceability codes to ensure product quality and regulatory
compliance. Thermal Transfer Overprinting (TTO) is a widely used technology in food packaging due to its high print
quality, flexibility, and ability to produce high-resolution, durable codes that meet legal and regulatory requirements. TTO
technology is critical for printing essential information such as batch numbers, expiration dates, barcodes, and traceability
codes directly onto packaging materials. The precision and versatility of TTO make it ideal for handling diverse packaging
formats and materials, including flexible films, labels, and laminated surfaces.
Thermal Transfer Overprinting (TTO) systems consist of several critical components that work in coordination to deliver
high-quality and precise prints on flexible packaging materials. At the core of the process is the thermal printhead, which
contains miniature heating elements that activate in a controlled sequence. When the printhead comes into contact with the
thermal transfer ribbon, it selectively heats specific areas to transfer ink onto the substrate. The platen roller supports this
process by holding the substrate—such as plastic film or paper—in place and ensuring consistent pressure and alignment
between the ribbon and the printhead. This alignment is essential for achieving uniform print quality across production
runs. The ink transfer ribbon, which serves as the medium for transferring print content, is available in various
formulations including wax, wax-resin, and pure resin. Each type of ink is suited to specific packaging materials and
durability requirements. The ribbon itself is housed in a ribbon cassette, which allows for smooth and controlled ribbon
movement during operation, minimizing slack and maintaining tension. The printing parameters, such as speed,
temperature, and alignment, are managed via the control panel or interface, which provides operators with full control over
the printing process. Additionally, sensors play a crucial role in detecting the presence of the substrate, thereby triggering
the print cycle only when material is correctly positioned. This prevents misprints and reduces ribbon wastage. Finally, the
coding window frame defines the physical area on the packaging where the print appears. This frame is often customized
based on the specific design of the film or label, allowing for accurate and consistent code placement during high-speed
operations.
However, the rising operational costs associated with TTO printing — including ribbon consumption, printer maintenance,
and energy use — pose significant challenges for manufacturers. Ribbon usage represents a major cost component in TTO
printing, as excessive ribbon consumption leads to increased material costs, higher printer downtime due to frequent
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ribbon changes, and elevated waste generation. Inefficient ribbon utilization not only increases production costs but also
contributes to a higher carbon footprint, making cost reduction strategies a priority for manufacturers seeking to enhance
profitability and sustainability. This research focuses on optimizing ribbon utilization to reduce printing costs in TTO
printing for food packaging. The study targets the Mini MM’s Biscuits (33g) SKU, which contributes significantly to the
overall printing volume and accounts for a major share of the production cost. Mini MM’s Biscuits SKU alone records
66% higher printing frequency compared to other SKUs, increasing the impact of inefficient ribbon usage. Existing
printing patterns involve continuous printing with single or double alignment, which leads to substantial ribbon waste and
limits production efficiency.
To address these challenges, this project explores three key optimization strategies: Letter height reduction, staggered
printing and coding window size adjustments. Staggered printing involves aligning multiple prints along the width of the
ribbon, allowing for increased ribbon utilization per pass and reducing waste. Adjusting the coding window size by
increasing the height creates additional space for staggered printing, which enhances print alignment and reduces the
number of ribbons passes required. Furthermore, introducing flexibility in font type selection and letter height ensures
compliance with both legal and FSSAI (Food Safety and Standards Authority of India) requirements without
compromising print clarity.
The proposed strategy is expected to reduced ribbon consumption by 49%, resulting in an estimated annual cost saving of
approximately ₹50.4 lakhs for the Mini MM’s SKU alone. Additionally, the reduction in ribbon usage is projected to
lower the carbon footprint by 46%, aligning with broader sustainability goals.
2. Objective
Reduce ribbon consumption by implementing staggered printing strategies that increase the number of prints per ribbon pass and
minimize material waste.
Optimize the coding window size by adjusting its height to allow for additional staggered prints, ensuring print clarity and
adherence to legal standards.
Achieve cost savings through reduced ribbon usage, extended printer lifespan, and minimized waste generation during the
printing process.
Ensure regulatory compliance by maintaining alignment with legal and FSSAI (Food Safety and Standards Authority of India)
requirements, while enhancing print legibility and traceability.
Improve printing efficiency by enhancing print alignment, reducing ribbon change frequency, and ensuring consistent coding
accuracy.
Enhance sustainability by decreasing the carbon footprint and reducing material waste through more efficient ribbon utilization.
3. Literature review
Thermal Transfer Overprinting (TTO) is a widely adopted technology in the food packaging industry due to its ability to deliver high-
resolution, durable, and legible prints on flexible packaging materials. Compared to traditional printing technologies like hot stamping
or continuous inkjet, TTO provides greater control over variable data printing, making it ideal for batch numbers, expiry dates,
barcodes, and regulatory codes. According to Johansson et al. (2012), the reliability and sharpness of TTO printing significantly reduce
misprints and enhance traceability, which is vital for compliance with food safety standards such as those mandated by the FSSAI
(Food Safety and Standards Authority of India).
Cost optimization in TTO printing has emerged as a critical area of interest, especially as packaging volumes rise and margins tighten.
Previous studies and technical manuals, such as those by Markem Imaje and Domino Printing Sciences, identify ribbon consumption
as one of the primary cost drivers in TTO operations. Excessive ribbon use results in both increased material costs and operational
downtime due to frequent ribbon changes. The inefficiencies in ribbon usage are often due to suboptimal coding window sizes,
oversized letter heights, and lack of staggered printing. As noted in Foley (2010), intelligent print layout and ribbon-saving strategies
can lead to significant reductions in consumable costs without compromising print quality.
Several optimization techniques have been proposed in industrial and academic research to tackle these inefficiencies. These include
reducing the letter height of printed characters, increasing the coding window height to allow for multiple staggered prints, and
adopting advanced print alignment software. Such strategies align well with lean manufacturing principles, where the focus is on
eliminating waste and enhancing process efficiency. In addition, emerging literature emphasizes the role of digital monitoring tools
that help track ribbon usage in real time, enabling proactive maintenance and predictive analytics to further cut costs.
However, despite the availability of such technologies, there is limited documentation on the real-world application of these methods
in medium-scale Indian food manufacturing environments. Many existing studies focus on high-end automation in multinational
facilities or provide generic recommendations without SKU-level analysis. This gap presents an opportunity to contribute practical,
quantifiable insights into how small adjustments—such as reducing letter height from 2 mm to 1.75 mm and expanding the coding
window by 5 mm—can yield significant cost savings and environmental benefits, as demonstrated in this case study of Mini MM’s
Biscuits (33g) SKU. Therefore, this research not only builds on existing knowledge but also bridges the gap between theory and
practical implementation in cost-sensitive manufacturing contexts.
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4. Methodology
The project adopted a structured methodology to analyse and optimize ribbon utilization in Thermal Transfer
Overprinting (TTO) for food packaging, specifically focusing on the Mini MM’s Biscuits (33g) SKU, which constitutes a
substantial portion of the company’s overall printing volume. The study began with the identification of key problems in
the existing TTO setup, where analysis revealed that only 17 mm of a 33 mm ribbon width was being utilized to
accommodate two staggered prints. This under-utilization resulted in significant ribbon waste.
To understand the scope of the issue, data was collected from various manufacturing units. This included monthly
production data for the Mini MM’s SKU, which averaged 3,500 metric tons, along with technical specifications such as
letter height, print length, and the dimensions of the coding window. Additionally, operational cost data covering ribbon
usage, machine maintenance, and production downtime was gathered to evaluate the financial implications of inefficient
printing practices.
The collected data was then analysed to pinpoint inefficiencies in the current process. It was found that high ribbon
consumption stemmed from suboptimal print alignment and limited use of ribbon width. As a result, only two prints per
ribbon pass were achieved, leaving nearly half of the ribbon unused. Based on these findings, a series of optimization
proposals were developed. These included reducing the font height, expanding the coding window area, and increasing
the number of staggered prints to enhance ribbon utilization.
Subsequently, controlled trial runs were conducted using the new font size and adjusted coding window dimensions.
These trials were evaluated through both visual inspections and compliance checks to ensure the print quality met
industry standards. A detailed cost-benefit analysis was then performed, comparing ribbon consumption and operational
costs before and after implementation. This analysis quantified the ribbon savings and projected the potential annual cost
reduction.
To ensure the proposed changes were viable for long-term use, the new process was validated for compliance with FSSAI
and legal packaging regulations. Lastly, the environmental impact of the optimization was considered. The improved
ribbon utilization led to a 46% reduction in material waste and carbon footprint, aligning the initiative with the
company’s sustainability objectives. Overall, the methodology ensured a comprehensive approach to enhancing cost-
efficiency and operational sustainability in TTO printing.
5. Problem Statement
At Narayana Foods Pvt. Ltd., the Mini MM’s Biscuits (33g) SKU contributes significantly to the company’s total
printing volume, making it a key focus area for operational optimization. However, the current TTO (Thermal Transfer
Overprinting) practices associated with this SKU are characterized by inefficient ribbon utilization. This inefficiency
primarily stems from suboptimal print alignment and a limited coding window size, which together lead to considerable
material waste and elevated production costs. Frequent ribbon changes, necessitated by high consumption rates,
contribute to increased machine downtime, thereby reducing overall productivity and raising operational expenses.
Several critical issues were identified during the preliminary analysis. First, the high rate of ribbon consumption, high
printing cost 0.25Rs/kg results from inadequate use of the ribbon's full width, causing excessive material waste. Second,
improper print alignment contributes to ribbon wastage and inconsistent print quality, often requiring reprints and further
increasing printing time. Third, the existing coding window has a restricted height, which limits the number of prints that
can be produced per ribbon pass, further reducing utilization efficiency. In addition, the frequent need to replace ribbons
disrupts production flow and adds to labour and maintenance costs. Finally, this inefficient use of consumables
negatively impacts the environment by increasing material waste and contributing to a higher carbon footprint.
To address these challenges, the project proposes a set of targeted optimization strategies aimed at improving ribbon
efficiency. These include reducing the letter height used in printing, implementing staggered printing techniques to
maximize the number of prints per ribbon pass, and enlarging the coding window to accommodate additional prints
without compromising compliance or clarity.
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6. Concept
Thermal Transfer Overprinting (TTO) for food packaging at Narayana Foods Pvt. Ltd. The research targets the Mini
MM’s Biscuits (33g) SKU, which represents a significant portion of the total printing volume and incurs high operational
costs due to excessive ribbon usage and inefficient printing patterns. The study targeted to counter these difficulties with
the help of few key actions to optimized the printing cost.
a. Flexibility in Font Type and Letter Height:
Adjusting font type and letter height ensures compliance with both legal and FSSAI requirements without increasing
ribbon consumption. Letter height adjustments include:2 mm (current) → 1.5 mm (proposed) → 1.75 mm (optimized).
b. Staggered Printing Strategy:
Aligning 2 or 3 prints along the width of the ribbon to maximize ribbon usage. Reduced unused ribbon space, increases
the number of prints per ribbon pass, and minimizes ribbon waste.
2mm Letter Height Two Stagger Print
1.75mm Letter Height. Three stagger print
c. Coding Window Size Adjustment:
Current coding window height is 19 mm which we have increased it by 5 mm allows for an additional staggered print.
Expanding the coding window size increased efficiency and reduced material waste.
Coding window height optimized by 5mm
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7. Conclusion
The research conducted at Narayana Foods Pvt. Ltd. confirms that optimizing ribbon utilization in Thermal Transfer
Overprinting (TTO) leads to substantial cost savings and improved efficiency. The key outcomes of the project include:
Improved ribbon area utilization by 12%
49% reduction in ribbon usage, resulting in significant material savings.
Reduced printing cost from 0.25 Rs/kg to 0.13 Rs/kg.
Estimated annual cost savings of ₹50.4 lakhs for the Mini MM’s Biscuits (33g) SKU along through staggered
printing and coding window adjustments.
46% reduction in carbon footprint due to lower material consumption, contributing to the company’s sustainability
goals.
The successful implementation of staggered printing and coding window adjustments demonstrates a practical and
sustainable approach to reducing printing costs and improving production efficiency in the food packaging industry.
8. References
1. A Guide to Graphic Print Production by Kaj Johansson, Peter Lundberg and Robert Ryberg.
2. Business Transformation: A New Path to Profit for the Printing Industry by John Foley
3. Food Safety and Standards (Packaging and Labelling) Regulations, 2011
4. The Legal Metrology (Packaged Commodities) Rules, 2011.
5. Markem imaje printing smartdate X40 Manual.
6. Printing 9020 Books for service engineer by Markem Imaje.
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