By Ben Starr, Technical Support Specialist, Luminite Products Corporation
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Packaging is important in today's world, as customers expect a certain experience when a product is shipped to their doorstep. Even the products packaged for sale on a store shelf are required to deliver a certain impression. Both flexo and gravure printing are reliable forms of product marking. However, each has its own benefits and downsides.
From print run length to color radiance, the printing method you choose can make a difference in cost and final product quality.
Advanced Printing Methods: Flexo vs. Gravure
Commercial printing relies on a variety of technologies to print on different substrates, but two of the more popular techniques are flexographic printing and gravure printing.
Both technologies involve the creation of printing sleeves, cylinders and plates, and both can perform long-run, high-volume printing ' though flexo can be cost-effective for shorter runs. Finally, both are able to produce exceptional results.
Below, we dive into the basics of each type of printing, then call out differences that are noteworthy.
Basics of Flexo Printing
Flexo typically utilizes a polymer or elastomer image carrier. This could be a:
The image carrier is engraved to create the raised design of the final desired print. Ink is then transferred from the inkwell via an anilox roller onto the image carrier, where it is then printed onto the substrate.
Flexo printing is more commonly associated with uses in flexible plastics and other non-porous materials such as film, labels, foil and other packaging. The ability to control and repeat the process for images printed using flexo is part of the appeal of this printing process.
Flexo is also noted for producing an exemplary print with fine lines and text detail.
Basics of Gravure Printing
The rotogravure printing process (commonly shortened to gravure) is a method of intaglio printing. Gravure printing works by applying ink to a substrate with the use of a metal plate that is typically mounted onto a cylinder. This plate is often made of copper or chrome.
The image or text that is intended for printing is typically laser etched into said metal plate, a process that often delivers high quality and precise results with good repeatability.
The gravure printing process also involves the transfer of the ink to the substrate from the depressions in the engraved surface. A blade removes excess ink prior to contact with the substrate. Meanwhile, an impression cylinder on the back side of the substrate forces contact with the depressed, ink-filled regions of the gravure roll.
The use of the impression cylinder increases color vibrancy in the print, which is another appeal of using this type of printing. The gravure press may include many in-line stations, each for a different color of ink. Additional stations may also be part of the process, which apply cold seal or barrier emulsions.
Flexo Printing vs. Gravure Printing: Where Differences Are Noted
Gravure ' Gravure image carriers are more expensive, making the number of prints required to break even much higher. Also, the lead time is three-four times that of flexo.
Gravure is better suited for printing on porous substrates and is considered ideal for high-detail printing on applications such as magazine covers. It has also been used in industrial-scale applications involving printed electronics. However, this type of printing has a limit to the number of inks that are compatible and also requires more ink per print ' which can drive up the cost of printing.
A type of printing traditionally associated with solvent-based inks, gravure printing could be considered less eco-friendly than a printing process that utilizes water-soluble inks (although the capabilities of these inks have been evolving and may be used in the future). The cost of printing can also be higher with gravure printing, due to the amount of ink required per print, although this is not always the case.
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Gravure printing was once considered best for fine detail and tonal work, but flexo technology is further enabling prints with higher resolution and detail as it evolves ' enabling it to move into print jobs that were previously associated exclusively with gravure.
Flexo ' Flexo printing has a much shorter lead time than gravure, which requires less frequent changing of the cylinder. The print run time for gravure is longer as well.
Flexo is able to print on both porous and non-porous substrates, making the technology ideal for everything from film to paperboard. When it comes to ink, flexo printing is the superior choice due to the ease of printing with a wider variety of inks.
Flexo is also commonly considered the 'greener' option. There are generally more flexo printing solutions for VOC (volatile organic compound) problems, and the press operations are associated with more environmentally friendly practices.
Flexo or Gravure: The Final Decision
Several factors, including sustainability, cost, ink type and more need to be considered before choosing between flexo and gravure printing. Your decision should be based on internal decisions mixed with outside consultations from your preferred printing house.
It's important to consult a trusted print house before making your final decision to ensure you will be getting the best prints possible.
About the Author
Resident Technical Support Specialist at Luminite Products Corporation, Ben Starr supports clients toward challenging printing applications, defects or press issues with his advanced knowledge of the flexograpohic printing industry. Family-owned and operated since , Luminite Product Corporation offers the original continuous print solution, as well as direct laser-engraved elastomer sleeves, cylinders and plates for the flexographic printing industry.
When it comes to modern commercial printing techniques, Flexographic printing and Gravure printing (also known as Rotogravure) are at the forefront. However, choosing between these two methods can be quite perplexing. In order to make an informed decision, it's important to understand the basics of both processes.
Flexo printing, or Flexographic printing, is a printing technique that utilises a polymer or elastomer as an image carrier. The raised impression on the image carrier, similar to letterpress, receives ink from the anilox roller. This enables a fast and efficient printing process, suitable for various applications.
Gravure printing is an intaglio printing process that involves copper-plated or chrome-plated cylinders with engraved designs, also known as cells, which hold the ink. These cylinders are then used to print the design onto the substrate using precise laser etching. The result is a high-quality printing output that is particularly well-suited for large print runs.
Several important factors come into play when comparing Flexo printing and Gravure printing. Let's examine these factors and their impact on both methods.
Flexo printing is known for its lower initial costs, making it more accessible for short-term printing requirements. On the other hand, gravure printing requires the use of expensive copper-plated cylinders, which may make it initially costlier. However, in the long run, gravure printing becomes more cost-effective due to the durability and longevity of these cylinders.
Lead time, or the time taken to complete a printing order, is a crucial aspect in the printing process. Gravure printing, with its laser etching technology, is significantly faster than Flexo printing. On average, gravure printing has a lead time that is three to four times faster than Flexo printing, making it more efficient for large-scale production.
Consistency in colour intensity is essential in commercial printing, particularly in continuous tone printing. Gravure printing excels in this aspect, as it ensures that the colour and print intensity remain consistent throughout the printing process. On the other hand, while Flexo printing can produce high-quality results, it may experience slight variations in colour intensity in continuous printing.
Ink compatibility plays a vital role in choosing a printing technique. Flexo printing offers a wider range of ink options, making it versatile and compatible with various ink sets. This allows for greater flexibility in achieving desired colour variations. Conversely, gravure printing restricts the use of specific inks, thus limiting the available colour range.
The substrate refers to the material surface on which the design is printed. Gravure printing works well with porous substrates such as magazine covers, providing sharp and vibrant results. However, Flexo printing excels in compatibility, as it can be used on both porous and non-porous substrates, making it more versatile for different printing needs.
Flexo printing has undergone significant advancements, making it a preferable choice in many aspects over gravure printing. It offers compatibility with all types of substrates, a wide variety of ink options, and lower initial costs. These factors make Flexo printing an excellent choice for commercial printing with high print loads or jobs requiring versatility.
For all your flexographic printing requirements, Anyflexo is your go-to destination. They provide top-of-the-line flexo components, along with customisable options, including a vast selection of ink colours to suit your specific printing needs.
Flexo and gravure printing are both modern and widely adopted printing methods, each with its own advantages and drawbacks. Determining which technique is better for your commercial printing needs depends on careful consideration of the factors discussed above. By assessing factors such as cost, lead time, continuous tone printing requirements, ink compatibility, and substrate compatibility, you can make an informed choice that aligns with your specific printing goals and budget.
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