GRAVURE PRINTING

DJP6052 – PRINTING FOR

PACKAGING
PREPARED BY : GIHA BINTI
TARDAN
PROCESS OF GRAVURE PRINTING
 The rotogravure process is a direct transfer method for printing onto wood-pulp
fiber based, synthetic, or laminated substrates, including:
 Films such as polyester, OPP, nylon, and PE
 Papers
 Carton board
 Aluminum foil
 The modern day rotogravure printing press uses a printing cylinder which has been
laser engraved with minute cells capable of retaining ink, the size and pattern of
which reflect the required image. These cells are forced to transfer their ink directly
onto the substrate by a combination of pressure and capillary action, so producing
the printed image.
 The process, also commonly called gravure printing, is used in the manufacturing of
food and non-food packaging, as well as labels, wall coverings, transfer printing,
and has a variety of further applications in the security printing, industrial, and
tobacco segments of industry.
ABOUT GRAVURE PRINTING @
ROTOGRAVURE
 Rotogravure printing or just simply gravure printing is a type of intaglio
printing process which uses a rotary printing press
 It involves engraving an image onto a copper plated steel cylinder base.
 A rotogravure printing press has one printing unit for each colour, typically
CMYK or cyan, magenta, yellow and key (printing terminology for black),
but the number of units varies depending on what colours are required to
produce the final image
 How does it work?
(Gravure Printing Process-i)
 Theink is applied directly to the cylinder and from the cylinder it is
transferred to the substrate
 While
the press is in operation, the engraved cylinder is partially
immersed in the ink fountain, filling the recessed cells.
 As the cylinder rotates, it draws ink out of the fountain with it. Acting as a
squeegee, the doctor blade scrapes the cylinder before it makes contact
with the substrate, removing excess ink from the non-printing (non-
recessed) areas and leaving in the cells the right amount of ink required:
this tool is located quite close to the substrate so that the ink left in the
cells does not have enough time to dry.
 How does it work?
(Gravure Printing Process-ii)
Next, the substrate gets sandwiched between the impression roller and
the gravure cylinder: this is where the ink gets transferred from the
recessed cells to the substrate
The purpose of the impression roller is to apply force, pressing the
substrate onto the gravure cylinder, ensuring even and maximum
coverage of the ink.
The capillary action of the substrate and the pressure from impression
rollers force the ink out of the cell cavity and transfer it to the substrate
Then the substrate goes through a dryer because it must be completely
dry before going through the next colour unit and absorbing another
coat of ink.
 Components of Gravure Printing
 Printing cylinder: a seamless tubular sleeve or full cylinder, made from either steel,
aluminum, plastic, or composite material, which is engraved with the image to be
printed.
 Doctor blade:  the device that removes ink from the non-engraved portions of the
printing cylinder and also removes excess ink from the engraved sections.
 Impression roller: a rubber covered sleeve that is mounted on a steel mandrel. Its
primary purpose is to press the substrate against the printing cylinder.
 Inking system: consisting of an ink pan, ink holding tank, and ink pump with supply
and return ink pipes.
 Drying system: consisting of a chamber which dries the ink once it is on the substrate
and prior to it reaching the next printing unit. Drier capacities are determined based on
the required printing speed, ink type (solvent or water based), and ink lay down
volume.
 MATERIALS USED.
 Paper
 Paper is a fibre-based material produced from wood, rags or organic material. The
types of paper used in the packaging and graphic arts industries typically use wood
and/or recycled paper and board, which is then chemically or mechanically processed
to produce cellulose pulp.
 Paper may be between 0.07 mm and 0.18mm thick, with paper for printing and
packaging applications generally being in a range between 60 and 120 gsm. The
crossover point between paper and board is normally considered to be around 160
grams per square meter (gsm), as it is only at this level that a fibrous material is likely
to be stiff and rigid enough to make a container.
 Paper has a wide range of industrial applications including use for the packaging of
products as diverse as confectionery and cigarettes, as a component in packaging
laminates, and for many commercial print uses.
 Carton board
 Carton board (also called cardboard, paperboard or solid board) is the name for a
range of paper based materials that includes folding box board (FBB, GC or UC),
solid bleached board (SBB, SBS, or GZ), solid unbleached board (SUB or SUS),
white lined chipboards (WLC, GD, GT, or UD), some unlined chipboards, and
certain laminated boards.
 The crossover point between paper and board is normally considered to be around
160 grams per square meter (gsm), as it is only at this level that a fibrous material is
likely to be stiff and rigid enough to make a container.
 Cartonboard is primarily used in the packaging industry to produce all types of
folding cartons, but may also be used for graphics applications. For folding cartons
the board used will normally be in the range 200 to 600gsm, or 350 to 800 microns.
 Film
 A film is usually characterized as a thin synthetic resin layer. There are many types of films
and their use depends on their physical and chemical properties, which make them especially
suitable for a given application.
 The most commonly used plastic films are low density polyethylene (LDPE), Polypropylene
(PP), bioriented polypropylene (BOPP), and polyester (PET).
 Printed film is used for packaging, display materials, stickers, seals, and a wide range of other
graphic applications.
 Films are generally characterized by their basis weight, expressed in g/m²; and thickness,
expressed in microns. For some films it is also useful to know their density, expressed in g/cm3.
 The increasing awareness of environmental issues is intensifying research into film substrates
derived from renewable sources that are compostable. 
 Aluminium foil
 Aluminum is produced from bauxite, an ore abundant in nature. From the rolling mill,
aluminum foils emerge with a natural shiny finish, almost as bright as a mirror, but
also can be produced with an as-rolled, satin-like finish called matte.
 Aluminum foil has all of the unique functional characteristics of the aluminum alloy
from which it is made.
 Because of its exceptional barrier properties, aluminum foil is used across a wide
range of flexible and other packaging applications to protect foods, drugs, cosmetics,
and a lengthy list of other items, most often in combination with other packaging
materials.
 Laminates
 A laminate is a material that can be constructed by bringing two or more layers of
material together. This can include different material combinations from a wide
spectrum of flexible substrates including thin aluminum foil, film, and paper. These
materials have different physical properties and varying thicknesses that combine to
provide the required barrier performance.
 Converted single- or multi-layer webs are used in a number of industries, from the
packaging of food and non food products to industrial applications including the
photovoltaic industry.
 The Strengths of Gravure Printing
 Very high printing speed and productivity are possible.
 Exceptionally fine halftone screens are possible.
 Excellent colour consistency over long print runs.
 Ink cells can be engraved to different depths allowing for the application of
different ink thickness.
 Heavy ink applications can be used to produce exceptionally bright and
glossy colours.
 Can print heavily pigmented metallic inks.
 Considered to be superior for printing skin colour and uniform heavy solids.
 Gravure cylinders are capable of printing several million repeats.
 Press make-ready is fast and production cost are modest.
 Gravure cylinders can be stored and remounted for repeat runs.
 The Limitations of Gravure Printing
 Cylinder preparation requires a long lead time.
 Cylinders are several time the cost of flexographic or lithographic
plates, making the process economical only for long runs.
 Does not print well on rough substrates such as uncoated
paperboard.
 Does not give good resolution of small type, fine lines and other small
details.
 Inventory and storage of base and engraved cylinders is costly.
 
IMAGE RESULT
Aluminium foil
QUIZ 2:
1) List all the parts of Gravure Printing in the picture (below?) (6 marks)
xxx
A

C
E

D
F

2) What is the major unit operations in a gravure printing operation?

(4 marks)
 Assigment:
1) Draw a simple diagram of Gravure Printing and explain the
process from beginning until the end.
2) Give all the ADVANTAGES and DISADVANTAGES of
Gravure Printing.
3) What kind of material that can be used to printed by
Gravure Printing?