Flexo Printing Vs. Gravure Printing
What is flexographic printing?
Flexographic printing, also known as flexo printing, is a relief printing technique, similar to letterpress whereby the ink is transferred from a raised printing plate using fast drying inks onto the chosen substrate. Flexographic printing is continually advancing, with improvements in the presses, plate making and ink technology all of which has increased demand for this method of printing in packaging.
Advantages of flexographic printing
Production speed – machinery runs at extremely high press speeds, even faster than rotogravure
Diverse applications – Flexography printing can be used on a wide variety of substrates including both paper and plastics.
Lower costs – plate costs are low thanks to developments in plate technology, so for small volumes flexography is less expensive than offset lithography.
Disadvantages of flexographic printing
Costs – The cost of printing plates can still be high for flexography, although the development of new plate materials has made the pricing more competitive
Print Quality – Flexo printing does not support continuous tone images, so is very difficult to achieve the same print quality possible with rotogravure, especially for complex artworks.
Colour Intensity – Colour vibrancy with flexography is not as strong and crisp as rotogravure printing
What is gravure printing?
Gravure printing or rotogravure is an intaglio printing process that uses rotary printing capable of producing continuous tone images. Large copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. The engravings are referred to as ‘cells’ and are etched in differing depths, with deeper cells providing more intense the colour.
Advantages of gravure printing
Intricacy – Gravure printing is the only high speed and volume print process capable of printing continuous tone images, also known as vignette effect
Print Quality – As a direct print process gravure printing results in better ink laydown and more consistent print quality
Production Speed – Printing times are quick, with modern presses able to produce up to 14m of film per second.
Durability – Gravure cylinders are extremely durable, can be used for several print runs.
Disadvantages of gravure printing
Origination costs – The initial cylinder set up costs can be very high. However, these costs are a one-off and when used for regular print jobs, cylinders will not need to be replaced for at least 18 months.
Production Costs – Gravure printing is not always as competitive on price as other printing methods, especially for shorter print runs but is very competitive when compared to Far East suppliers
High Order Volumes – Set-up costs will demand higher minimum order quantities for rotogravure printing but MOQ’s have considerably lowered in recent years
