Rethinking Print Layouts: Smarter Planning and Imposition with Esko Phoenix
Written by Alexandra Blanck
Content Manager, Esko
Packaging production is changing fast.
More SKUs. Shorter runs. Last-minute changes. And, of course, customers who expect it all to be delivered yesterday — with zero waste and flawless quality.
But there’s a silent productivity killer hiding in plain sight: manual, outdated planning and imposition workflows.
If you’re still building layouts in spreadsheets or juggling disconnected tools, you’re not alone, but you’re also not going to be able to compete with those who don’t.
It’s time for a better, more efficient way.
But first, what is planning and imposition in packaging?
Planning and imposition involve arranging multiple packaging designs onto a single print sheet in the most efficient and cost-effective way.
This process accounts for different packaging types, print specifications, die cuts, substrates, and finishing needs.
This all has to happen before a job hits the press.
In the world of packaging, where SKUs are exploding and job runs are shrinking, effective planning and imposition ensures minimal material waste, optimized press utilization, and predictable delivery timelines.
The Growing Complexity of Print Layouts
Today’s converters and printers face a tough balancing act: managing more custom jobs and shorter runs, while maintaining profitability and speed.
For example, each variation in size, shape, or substrate can impact how items are laid out, which increases the workload on planners and increases the risk of human error.
Consumer demands also drive complexity because brands want to deliver flexibility, quick changes, and sustainable outcomes.
All these factors put added pressure on prepress operations to deliver high-performance results.
The Hidden Cost of Inefficient Planning
Prepress layout isn’t a flashy process. In fact, it doesn’t involve presses or packaging lines.
It does, however, play a huge role in whether your jobs run profitably — or not.
When layouts are built manually, you risk:
- Wasted material from inefficient ganging
- Lost time to trial-and-error nesting
- Costly errors in quantity calculations
- Slow response to customer changes
And when every job is different, complexity can spiral quickly.
What’s the Solution?
Automating layout planning sounds good, right?
Unfortunately, traditional software only gets you part of the way there. Rules-based templates are static. They don’t adapt.
And they definitely don’t help you make smarter trade-offs between waste, cost, and efficiency.
That’s where Phoenix comes in.
Phoenix is a powerful CAD-based nesting and imposition software for sheet-fed and roll-fed carton and label production.
In fact, it’s the printing industry’s first and only automated, AI-driven pre-production solution for packaging and labels.
Phoenix integrates intelligence into the imposition process — using AI to do what humans (and rigid templates) can’t.
It analyzes every variable in a job and instantly proposes the most optimized layout.
Less waste. More jobs. Higher margins.
Let Phoenix Rise Above
At its core, Phoenix is built to solve the challenges that planning and prepress teams face every day, including:
AI-Driven Imposition
No more guesswork. Phoenix uses intelligent algorithms to automatically create the best layout for each job — balancing efficiency, cost, and production constraints.
Dynamic Nesting & Ganging
Combine different designs, sizes, and quantities onto one sheet or roll without compromising print quality or finishing.
Smart Estimating
Generate fast, accurate layout proposals for quotes — allowing sales teams to win more jobs with confidence.
Connected Workflows
Integrate with your MIS, ERP, and other Esko products to eliminate double work and keep everything in sync.
Why It Matters
When you optimize planning and imposition, you’ll experience myriad benefits, including:
- Faster job turnaround
- Fewer material overruns
- Smoother press utilization
- Better alignment with sustainability goals
It’s not just about saving time. It’s about scaling without chaos.
Designed for the Real World
Whether you’re a packaging converter juggling dozens of SKUs, a digital printer managing short-run variability, or an operations lead trying to meet aggressive sustainability KPIs — Phoenix helps you take control.
It replaces outdated ways of working with repeatable, standardized processes.
Phoenix empowers planners to focus on strategy, not busy work.
The Bottom Line
If you’re still relying on old methods to plan your print jobs, you’re leaving time and money on the table.
Ready to explore what Phoenix can do for your business?
About the Author
Alexandra Blanck, a member of the Esko Corporate Marketing team, is known for her dedication to crafting engaging content that resonates with global audiences. As a Content Manager, she brings a strong editorial perspective and strategic insight to Esko’s communications, with a passion for turning complex topics into compelling narratives. Beyond her work at Esko, Alexandra is known for her creativity and storytelling expertise with a diverse writing portfolio that spans lifestyle features, fiction, and poetry.
