How Many Thermal Rolls Can You Make from One Jumbo Roll?

Whether you are a paper roll converter or distributor and wholesaler in the industry, you probably know that small thermal paper rolls are made from thermal jumbo rolls, which are also called mother rolls or slitter rolls in some cases. You might also want to know how many small finished rolls can be produced from a single jumbo roll.

Understanding this helps you plan your material procurement and evaluate your production efficiency if you are running your own paper roll factory, and it also gives you a clear picture of how thermal paper roll prices are formed. In this article, we will walk with you through the process step by step.

Key Terms You Need To Understand First

• Jumbo roll: The large paper roll used in production.
• Slitting width: The actual width you cut on the slitting machine.
• Trim: The paper lost due to the edge trimming.
• GSM: Gram per square meter, also known as basis weight. For this guide, we use 60 g/m² as a common reference.

If you understand these basics, we can go on to the question.

Thermal jumbo rolls Image: Panda Paper Roll

1. How Many 80mm x 80mm Thermal Rolls Come from One Jumbo Roll?

As one of the highly demanded paper roll sizes, the 80mm x 80mm thermal paper roll dominates the majority of the market share. At Panda Paper Roll, we export approximately 10 to 15 containers of 80mm x 80mm thermal rolls to our global customers every month. This paper roll size is compatible with all 80mm (3 1/8 inch) standard receipt printers, including Epson, NCR, Brother, Uniwell, Sharp, and a number of other POS receipt printers.

At Panda Paper Roll, we normally use 558mm x 6000m jumbo rolls to produce 80mm x 80mm thermal rolls. The question now is – how many 80mm x 80mm rolls are produced from one 558mm x 6000m jumbo roll?

Calculate by the Length Method

Blades on slitting machines Image: Panda Paper Roll

The 558mm width jumbo roll is cut into 7 rows Image: Panda Paper Roll

To calculate this, you can check the above photos, and we can clearly see that:

• The jumbo roll is cut into 7 rows (558 mm ÷ 79 mm) in the row orientation. The extra 5mm is left as trimming.
• For each 80mm x 80mm 60gsm paper roll, it has a 60m length, while the jumbo roll length is 6,000 meters. That means we can produce 100 rolls per row (6,000 m ÷ 60 m = 100).
• So the total rolls will be 7 rows × 100 rolls/row = 700 rolls in total.

That means we can get around 700 rolls of 80mm x 80mm thermal paper from one 558mm x 6000m jumbo roll.

Verify by Weight Method

To verify if we are calculating this correctly, we can use the weight method to check.

• For one roll of 80mm x 80mm thermal paper, the weight is 0.284 kg (0.079 x 60 x 0.060 = 0.284 kg).
• For one jumbo roll, the weight is 200 kg (0.558 x 6000 x 0.060 = 200 kg).
• So we can get 704 rolls (200 ÷ 0.284 = 704) from one jumbo roll.

This matches closely with the first calculation using the length method.

Of course, there will always be a small tolerance in both methods, since some paper is lost during production,  such as trimming, setup, and rewinding waste. But these calculations give you a clear, realistic estimate of how many 80mm x 80mm rolls you can produce from one jumbo roll.

2. How Many 57mm x 40mm Thermal Rolls Come From One Jumbo Roll?

If you are a seasonal paper roll distributor and trader, you should also know that the 57mm x 40mm thermal paper roll is another popular paper size. They are widely used in credit card terminals, mobile POS devices, and portable receipt printers. Many customers order this size together with 80mm x 80mm rolls because they are often used in the same retail or restaurant environments.

At Panda Paper Roll, we typically use 565mm x 6000m jumbo rolls to produce 57mm x 40mm rolls. So, the question is – how many 57mm x 40mm rolls can we make from one 565mm x 6000m jumbo roll?

Calculate by the Length Method

The 565mm jumbo roll is cut into 10 rows Image: Panda Paper Roll

From the photo above, you can see that:

• The jumbo roll is cut into 10 rows (565 mm ÷ 56 mm = 10). The extra 5mm is lost as trimming.
• For 57mm x 40mm 60gsm thermal paper, it has a length of 12 meters, while the jumbo roll length is 6,000 meters. That means we can get 500 rolls per row (6,000 m ÷ 12 m = 500 rolls)
• So with the same method as above, we can get the total rolls = 10 rows × 500 rolls/row = 5,000 rolls.

That means we can get 5,000 rolls of 57mm x 40mm thermal paper from one 565mm x 6000m jumbo roll.

Verify by Weight Method

With the same weight method, we can verify if we are calculating this correctly:

• The weight of one 57mm x 40mm roll = 0.040 kg (0.056 × 12 × 0.060 = 0.040 kg)
• The Weight of one jumbo roll = 200 kg (0.565 × 6000 × 0.060 = 200 kg)
• So we can get total rolls = 200 ÷ 0.040 = 5,000 rolls

This result perfectly matches the length-based calculation.

Once again, this result is for estimation purposes only. The final output may vary depending on your slitting machine accuracy, blade quality, operator skills, and many other factors.

👉 Try Our Free Online Tool

To make it easier for you, we have also created a free online calculator that will help you calculate an estimate of how many small paper rolls you can get from one jumbo roll. You just enter the data needed, and the calculator will automatically provide the answer.

Conclusion

Understanding how many small rolls you can get from one jumbo roll is crucial because you will know how many jumbo rolls you need to prepare for your customers’ orders. This knowledge also lets you monitor your production rate. For example, if you know your jumbo roll should produce 5,000 rolls and your employee only produces 4900 rolls, your production rate is 98%.

Now, do you clearly understand these two questions?

• How many 80mm x 70mm thermal rolls can come from one 636mm x 5800m jumbo roll?
• How many 57mm x 50mm thermal rolls can come from one 565mm x 6000m jumbo roll?

You can leave your comment below to answer the questions. If you still have any questions or comments, please feel free to contact us at support@pandapaperroll.com.