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.
This post is designed to take a closer look at the key differences in flexo printing vs. gravure printing. Better understand these two printing technologies will ensure that you use the right process for your application.
(ICYMI: We've also discussed the differences between Flexo Printing and Offset Printing.)
Flexo Printing Vs. Gravure Printing:
The disadvantages and advantages of gravure printing and flexo printing involve several factors:
Cost and lead time
Substrates
Ink
Environmental considerations
Quality
For those not familiar with one or the other, here's a quick rundown of the flexo and gravure printing processes:
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.
Flexo is noted for producing an exemplary print with fine lines and text detail.
Have questions on Flexographic basics? Check out our new Flexo 101 resource hub below:
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 Similarities
But before we get into the differences, however, let’s take a look at a few key similarities:
Both technologies involve the creation of printing sleeves, cylinders, and plates.
Both can perform long-run, high-volume printing, though flexo can be cost-effective for shorter runs.
Both are able to produce exceptional results.
Flexo Printing vs. Gravure Printing: Key Differences
Now that we’ve gone over the similarities between flexo and gravure, and explained the basic process of each, it’s time to take a look at some of the key differences:
Cost and Lead Time:
Gravure image carriers are typically much more expensive than flexo image carriers, making the number of prints required to break even much higher. Gravure, however, has a longer press run time, as the cylinders do not require as frequent changing as those in the flexo printing process.
Gravure lead time is usually 3-4 times that of flexo in the time it takes to manufacture the image carrier.
Substrates:
One of the limitations of gravure printing is that it is generally better suited for porous substrates. This is one of the reasons that gravure is best suited for high-detail printing on applications such as magazine covers.
That isn’t the case with flexo printing, which is able to print on both porous and non-porous substrates, making the technology ideal for everything from film to paperboard. In you're specifically measuring flexo vs. gravure in packaging printing, you'll usually find that flexo wins.
Inks:
Another key differentiator in flexo vs. gravure is the range of inks flexo is able to print with. Gravure printing problems include a limited number of inks with which it's compatible. In most cases, flexo printing ink is the superior choice due to the ease of printing with a wider variety of inks.
Gravure requires much more ink per print, which can drive up the cost of printing.
Environmental Considerations:
Due to the fact that gravure is traditionally associated with solvent based inks (although water based ink capabilities have been evolving), flexo is commonly considered the “greener” options.
There are generally more flexo printing solutions for VOC (volatile organic compound) problems, and the press operations are associated with more environmentally friendly practices.
Quality:
Gravure 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.
Consider the other pros and cons of gravure printing and weigh them against the slight (if any) difference in end quality you'll get with flexo.
Flexo or Gravure: The Final Decision
As you can see, there are many differences between flexo and gravure printing.
Which process is right for you? It largely depends on the job, substrate, and a variety of other factors of the job you're printing. Don't substitute one printing process for the other without thinking it through with your internal team and an external printing expert.
(Editor's note: This blog post was originally published in August 2018 and was updated in March 2023 to reflect current and up-to-date information.)
So, you’ve been tasked to source the most cost-effective packaging, without compromising pack quality. Trying to find the perfect format, features, materials and finishes can be a headache. Add to this the crucial decision on printing methods and we can understand why you’d feel a bit lost.
Our team have created this helpful guide to explain the pros and cons of the most common print technologies used in packaging to answer the simple question: flexographic printing vs gravure printing – what’s the difference?
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 have increased demand for this method of printing in packaging.
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 a more intense colour.
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
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 the 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 and 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 in 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 MOQs have considerably lowered in recent years
What’s best for your packaging?
We admit it can be difficult to understand the real difference between flexographic print and gravure print. Unless you have a sample of an identical artwork in flexo and another in gravure you won’t always truly appreciate the vast improvement gravure print can make to the overall look and feel.
The balance between cost and quality always involves difficult compromises for brands. At Law Print Pack we use up to 12 colours of flexographic printing in the manufacture of paper bags. However, when it comes to flexible packaging we believe that the finished quality of gravure printing far outweighs what can be achieved by flexo.
Want more information on Flexographic printing vs Gravure printing? If you’re looking to convince your team that gravure printing is worth the investment and need some support, then click here or contact our team today at +44 (0) 161 440 7302.
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