1. Make all objects in the same row and same column the same size (Ctrl+Click all objects, right click, select Size, Same Size)
  2. Remove any spaces between fields/objects in the report
  3. Suppress all blank sections
  4. In Crystal Reports 8.5 right click any section and select Format Section. Unmark Free Form Placement on all report sections to improve the export to Excel. Unmarking that option will force you to place objects in your report in a grid of rows, and this will export more cleanly to Excel.
  5. Set your printer settings (File, Page Setup, Paper Size) to a wide page size (example: A3 landscape). This can give extra columns that may be needed for the Excel Export. (You do not need to have the wide physical printer on your network.)
Exporting to Excel creates extra row between each valid row of data

When a Crystal Report has a "Details a" and "Details b" section with each being conditionally suppressed, the following issue may occur after exporting to Excel.

In Excel:
Row 1

Row 2

Row 3


In Crystal Report:
Row 1
Row 2
Row 3
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When a Crystal Report has a "Details" section containing a subreport in this "Details" section in Excel you may get the following:

In Excel:
Row 1

Row 2

Row 3

In Crystal:
Row 1
Row 2
Row 3
 
Try the following steps until issue is resolved:
  1. If using multiple Details section with fields in each one, move the fields from one section into the other (place one field on top of the other)
  2. Delete the extra Details section and conditionally suppress the fields (rather than suppressing the sections)
  3. Right click on the Report Header section and select Section Expert
  4. Unmark Free-Form Placement checkbox
  5. Mark Suppress Blank Section
  6. Repeat steps 4 and 5 for each section in the report
  7. Click OK
Also, try suppressing other blank sections (Report Header or Report Footer sections).
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If your report in Crystal has a subreport move the fields out of the subreport into the main report if possible (replacing the subreport).