RU
EN
CN
Difference Between Rotogravure and Flexographic Printing
Date: Dec 09 2024 From: Star Color Views:
1. Printing Process
Rotogravure Printing:
Rotogravure is an intaglio printing process, where the image is etched onto a cylinder. The engraved areas, or cells, hold the ink, which is transferred directly to the substrate (such as paper, plastic, or foil) as it passes through the press.
Ink Transfer: Ink is picked up from a reservoir by the engraved cylinder, and excess ink is wiped off with a doctor blade. Only the ink in the engraved cells is transferred to the substrate.
Key Feature: High-precision, consistent image quality, ideal for fine details and vibrant colors.
Flexographic Printing:
Flexographic printing is a relief printing process that uses flexible rubber or photopolymer plates. The raised areas of the plate carry the ink, which is transferred to the substrate.
Ink Transfer: Ink is supplied by an anilox roller, which regulates the amount of ink deposited on the plate before it is transferred to the substrate.
Key Feature: Versatility in printing on various surfaces, including non-porous materials.
2. Substrates and Applications
Rotogravure Printing:
This method is ideal for long-run jobs with consistent quality requirements. Common applications include:
Packaging for food, beverages, and pharmaceuticals.
Decorative printing on wallpapers and laminates.
Magazines and high-volume publications.
Flexographic Printing:
Flexographic printing excels in flexibility and is suitable for a wide range of substrates, including:
Flexible packaging (plastic films, paper, foil).
Labels, tags, and cartons.
Corrugated boxes and paper bags.
3. Ink Usage
Rotogravure: Typically uses solvent-based or water-based inks. The ink formulation must be optimized for quick drying to suit high-speed printing.
Flexographic: Can use water-based, UV-curable, or solvent-based inks, offering greater environmental options and lower costs in some cases.
4. Printing Speed and Efficiency
Rotogravure: Known for its high-speed capabilities, making it ideal for very large-volume runs. However, the setup and cylinder engraving are time-consuming and costly.
Flexographic: Offers faster setup times and lower initial costs. While not as fast as rotogravure for long runs, it is more cost-effective for short-to-medium print volumes.
5. Image Quality
Rotogravure Printing: Produces high-resolution prints with excellent consistency and vibrant colors, making it suitable for premium packaging and detailed designs.
Flexographic Printing: Delivers good quality prints, but historically, it fell short of rotogravure for fine details. Modern advancements, however, have significantly improved its resolution.
6. Cost Implications
Rotogravure:
High initial costs: Cylinder engraving and setup are expensive.
Economical for large volumes: Cost per unit decreases significantly with higher production volumes.
Flexographic:
Lower setup costs: Photopolymer plates are cheaper than engraved cylinders.
Versatile: Cost-effective for shorter runs and variable designs.
Which One to Choose?
Choose Rotogravure if: You need high-quality, consistent prints for large-volume jobs and can accommodate higher initial costs.Choose Flexographic if: You require a flexible, cost-effective solution for short-to-medium runs, or need to print on diverse substrates.
