Limitations Advantages

Flexgraphy Printing
Flexographic printing is faster than rotogravure.
Another advantage of flexographic printing is its versatility. It can be used on nearly any non-absorbent material.
It is a great option for text printing on pouch bags.
An advantage of flexography is that is a fast and economical method to print relatively simple designs on stand up packagi
It supports a range of colors.
It can be used with water-based inks as well as oil-based inks. Currently water-based inks are popular because of their non

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 exp
offset lithography

On the downside, flexographic printing is not very advanced. It cannot produce complicated and extensive artwork as com
that produced by rotogravure printing.
The colors in the final product of flexographic printing are neither as bold nor as crisp as they are in rotogravure printing.
The whole process is less dynamic than rotogravure. This is partially because flexography is old. Rotogravure is a relatively
technique. It is better suited for the 21st century.

If you want high-end images on your pouch, rotogravure is the way to go.
Despite a clear disadvantage, there is no shortage of businesses that opt for flexography. Quick evaporation of inks in flexo
makes it a safe alternative for flexible food packaging. Today, flexographic printing is still used in milk cartons, candy bar w
envelopes, and even newspapers.

Disadvantages of flexographic printing

Costs – The cost of printing plates can still be high for flexography, although the development of new plate materials has m
pricing more competitive
Print Quality – Flexo printing does not support continuous tone images, so is very difficult to achieve the same print quality
with rotogravure, especially for complex artworks.
Colour Intensity – Colour vibrancy with flexography is not as strong and crisp as rotogravure printing

What is the Difference Between Flexo & Gravure Printing?

COST AND LEAD TIME:

Gravure image carriers are typically much more expensive than Flexo, making the number of prints required to break even
higher. Gravure, however, has a longer press run time as the cylinders do not require as frequent changing as Flexo.

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 generally better suited for porous substrates. This is one of the reasons
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 techno
everything from film to paperboard.

INKS:

Another key differentiator is the range of inks Flexo is able to print with. Gravure is more limited in the inks that it works w
making Flexo 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 printin
Rotograure Printing
Intricacy – Gravure printing is the only high-speed and volume print process capable of printing continuous tone images, a
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
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 p
compared to Far East suppliers

High Order Volumes – Set-up costs will demand higher minimum order quantities for rotogravure printing but MOQs have
1) In-Line Press

Suitable for narrow web and mid-web printing, the sturdy in-line press is a popular choice
for printing on a range of substrates. Individual colour stations are stacked in line
horizontally from front to back. In –Line presses are very versatile and can integrate new
technology with greater ease than the other systems we will look at. In-line presses are
great for wider width printing. Reverse-side printing is made easy in some machines by
turning bars that rotate the substrate without having to change the print cylinder. A variety
of additional processes can be added in combination with flexo to add value to a printed
product such as Foil blocking, Cold foil, Laminating.

2) Central Impression Press

Central Impression Presses are suitable for narrow web printing and are the most
commonly used flexographic print machine for unsupported substrates . Typically 4 to 10
colour stations are possible , but instead of arranging them in line, each colour is positioned
as a satellite around the main Central Impression cylinder. The Central cylinder can be over
a metre in diameter. These types of machine have an advantage of being compact if space
is an issue. They also provide very stable register on all types substrates. They are not as
efficient as in-line presses or as operator friendly. Printing on both sides of the substrate
may involve reducing the available printing width by 50% .

3) Stack Press

Stack presses provide the advantage of a compact footprint like the CI press . They are
however the black sheep of the flexographic printing family being difficult to operate a
stack of four to eight vertical colour stations and requiring a ladder to get to the upper
print stations. The substrate follows on a snake like journey through the stack; the colours
being imprinted on the substrate as it is passes through each station. This makes it difficult
to monitor production quality during a long print run .Stack presses can comfortably handle
most supported webs but are not suitable for unsupported materials
Flexo Printing Vs. Gravure Printing:

The disadvantages and advantages of gravure printing and flexo printing involve several factors:

1. Cost and lead time

2. Substrates
3. Ink
4. Environmental considerations
5. Quality

For those not familiar with one or the other, here's a quick rundown of the flex

BASICS OF FLEXO PRINTING

Flexo typically utilizes a polymer or elastomer image carrier. This could be a:

Sleeve
Cylinder
Plate

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.
Flexo Printing vs. Gravure Printing: Key Differences

infographic-flexo-vs-gravure
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:

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 reasons that gravure is best suited for high-detail printing on applications such as magazine
covers.
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:
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:
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.
's a quick rundown of the flexo and gravure printing processes:

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 can
Both technologies involve the
perform long-run, creation ofprinting,
high-volume printing though
sleeves,flexo
cylinders,
can beand plates.
cost-effective for
shorter runs.
Both are able to produce exceptional results.