Quick Coating Usage Formula Steps

Step 1:

(Sheet Width × Sheet Length) ÷ 144 = Area per Sheet (ft²)

(Width and Length must be in inches.)

Step 2:

Area per Sheet × Number of Sheets = Total Area (ft²)

Step 3:

(Total Area ÷ 1,000) × Coating Weight per 1,000 ft² = Total Pounds Needed

🔥 Quick rule of thumb for coating weight per 1,000 ft² by Anilox BCM:

• 3 BCM ≈ 1.3 lb

• 4 BCM ≈ 1.8 lb

• 5 BCM ≈ 2.2 lb
  (These are "good average" numbers for flood coating.)

Step 4 (Optional):

Total Pounds ÷ Coating Specific Gravity (lbs per gallon) = Gallons Needed

Most UV coatings weigh 8.5–9.0 lb per gallon. (Check your product data sheet for exact weight if you want it super accurate.)

In short:

Coating Pounds Needed = (Sheet Width × Sheet Length ÷ 144) × Number of Sheets ÷ 1,000 × Pounds per 1,000 ft² based on BCM

Gallons = Pounds ÷ 8.75

Super Simple Example:

Let's run yours again fast with this:

• 16.375 × 9.5 ÷ 144 = 1.08 ft² per sheet

• 1.08 × 30,000 = 32,400 ft²

• 32,400 ÷ 1,000 = 32.4

• 32.4 × 1.8 (for 4 BCM) = 58.32 pounds

• 58.32 ÷ 8.75 = 6.7 gallons

Note: 

The Quick Coating Usage Formula provided above is intended for general estimation purposes only. Actual coating consumption can vary based on multiple factors, including but not limited to substrate absorbency, coating viscosity, press speed, transfer efficiency, anilox roll condition, and application method.

Always conduct on-press testing and verify material requirements before production to ensure sufficient supply. Phoenix Inks and Coatings assumes no liability for shortages, overages, or production issues resulting from reliance on this calculation.