Flexo – Indirect printing. Read on to know what’s right for your budget. Flexo Printing Process vs. Rotogravure. Flexo Printing Process vs. Rotogravure. Read on to know what’s right for your budget. Worth noting is that you should be leaning to brand new machines instead of used ones. Worth noting as well is that rotogravure printing is better for shorter runs because the cost of the cylinders is lower. In making your decision when it comes to choosing for the right printing technique to use for your corporate needs, two things must be at the top of your head: quality and affordability. with a lot of local manufacturers of printing presses. Right after the Gutenberg Press popularized movable type back in the 15th century, letterpress had been the predominant printing technique for five centuries. The first step in flexographic printing is designing your artwork. })(document, 'script', '//demo.citrus.ph/?p=134&ph_apikey=42de92a5dd4ac09fe15ae8f8c85302a6'); Copyright Lead Yuan Flexo 2019 | Powered by: Citrus.ph, Hi! Both commercial printing methods are great at producing high-quality and high-resolution prints. The average storage area you need for flexographic plates, anilox, and sleeves is 200 square meters. • Direct printing process gave the best print quality. It’s more versatile and … Advantage gravure. ph.type = 'text/javascript'; Rotogravure printing uses metal plates to transfer images onto the desired substrate. Two of the most popular printing processes are flexographic and offset printing. If deciding to use custom labels for marketing, you may already know that there are a number of different printing options available. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. Producing these products generally takes 3 steps: 1. But flexographic printing is more efficient for longer production runs, having fast lead times, fewer ink costs, and reduced energy consumption. The … As every printing job requires a different set of needs, there are several factors to be taken into account when choosing the right printing technology. In evaluating the two examples, it's evident that in "Example A" the cost of flexo vs. rotogravure is equal after two production runs. By some estimates, the industry may see a decrease as high as 18 percent between 2014 and 2024. Flexographic printing works on a wider range of substrates, including non-flat media. Click one of our member below to chat on. Gravure printing; Coating volume: Approx 4g/㎡ (wet) Number of plates: 175lpi 250lpi: Ink type: Solvent or Water based: Plate material: Iron (alturminum) core + plating: Exhaust VOC: Combustion: Viscosity: 15 – 17 seconds (No.3 cup) Flexo printing . Trying to find the perfect format, features, materials and finishes can be a headache. Bulk printing is a tedious task and does require some level of optimization. Letterpress printing: the process explained. Today, there are two main types of printing: rotogravure and flexographic. Gravure Versus Flexo Printing-Part 1 Published: July 01, 2009, By By David Argent Contributing Editor Gravure and flexo, two primary printing processes, continue to compete head to head in the packaging market segment. … In the case of flexo, there are pre-press costs associated with each run, as the following examples will show. Disadvantages. The high efficiencies associated with low cost gravure inks and high running speeds. However, one outweighs the other when it comes to costs. Reading Time: 3 minutes So, you’ve been tasked to source the most cost-effective packaging, without compromising pack quality. Aqueous coating vs. traditional overprint varnish: • Good gloss • Increased rub resistance • Smoother feel • Elimination or reduction of spray powder applications • Faster handling of the printed products • Decreased application time. This is the image carrier and contains all the text or images which eventually get printed on the substrate. Lithography production costs more, and presses can be very expensive. Printers and label makers use four main types of printing processes packaging: flexographic, digital, gravure, and offset. 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. This printing technique allows a lot of flexibility with label material. Rotogravure printing, also known as gravure, is a printing process that uses rotary printing. • Direct printing process gave the best print quality. There are significant disadvantages to purchasing a used flexo press. So all the raised surfaces on a cliché make the image of the run. President Colors can be produced with shading. The flexographic print process has enjoyed a period of continual development, elevating its reproduction capabilities far beyond what has traditionally been possible, and putting it in the same perceived level of gravure and offset printing. The production process also costs much less. Digital printing is a mainstay for smaller printing jobs, but also be aware that this form of printing might not be the best option. The only difference is the versatility of use and cost of production. Etiam sit amet orci eget eros faucibus tincidunt. The choice depends on the type of output (packaging applications including flexo-printing have other requirements than commercial printing on offset systems) and the degree of interactivity or automation. Flexography, on the other hand, uses a rubber plate with a raised surface. Flexographic printing, or Flexo, is a technique for bulk printing using flexible relief plates.Lithographic printing or Litho is a method of printing, initially based on the unmixable materials of oil and water. This setup is for a typical long run (more than 12,000 labels) application. Gravure and flexographic printing are essentially in-line processes. Though these two have the ability to print high-quality images on a vast array of substrates, they differ in terms of production cost. Gravure is gradually losing market share to offset for publication printing and to flexo for packaging applications. Both commercial printing methods are great at producing high-quality and high-resolution prints. In evaluating the costs of various printing process for the packaging industry, it's important to evaluate the costs based upon the repeat runs that are common for many packaging products and not just the initial cost associated with the pre-press. Two technologies that are often compared are letterpress and flexo printing. The printing cylinder is inked and the ink is moved onto the paper medium. Digital Printing vs. Flexographic Printing. These plates are flexible photopolymers that are positioned around web press cylinders that rotate. Therefore, rotogravure printing with its higher first-time cost had to be justified over a longer run, hence the adage: Unlike publication printing, packaging normally consists of multiple production runs. See the full range of CDI Spark and CDI Crystal imagers So, when looking at the real cost, there is quite a potential savings in pre-press cost for rotogravure, when products are re-run multiple times throughout the year. Aside from the pre-press costs, printers should also consider some of the other advantages of rotogravure: Dick Chesnut The plate is inked, with the inked image being moved to the printing surface afterwards. This enables you to pile them on top of each other for easy and safe storage while saving on space and shelving. As the name suggests, flexo printing utilises flexible plates for a rotary printing process. There is a CDI for every need: from narrow web label printing, to flexible packaging and wide format corrugated printing; from one color printed corrugated boxes to highly sophisticated multi-color packaging and even security printing. The cost of storage investment would be higher for the rotogravure process than the flexographic process. Each type of printing has a niche or application where it is best suited. Phone: (973) 227-6995 Flexographic printing works on a wider range of substrates, including non-flat media. Package printing comes in many shapes and sizes. Gravure presses have individual print stations arrayed linearly. The former can run at 300-500 meters per minute. Flexographic printing and rotogravure printing may be two of your best options. Flexographic vs. Gravure Printing. An imager for every need: from CDI Spark to CDI Crystal. Rotogravure printing materials require more thought and space in terms of storage. Read on as we discuss the differences between these techniques and figure out why they are the most popular in the industry. Advantage gravure. Disadvantages. Flexographic printing vs gravure printing what’s the difference? Offset and flexographic printing are two of the most popular printing methods in packaging when high-quality, consistent, and long-run jobs are a must. Flexography, on the other hand, uses a rubber plate with a raised surface. Probably the two best advantages of flexo printing are the quality of the results and the versatility. Even with rotogravure printing machines standing alone on the stage of “gold standard” printing quality, it cannot be denied that when compared to flexographic printing, an individual is expected to have his/her doubts. • Cylinder making technology widely available • Huge support from local ink suppliers. High-quality flexographic printing has never been as easy as it is today. Offset and flexographic printing are two of the most popular printing methods in packaging when high-quality, consistent, and long-run jobs are a must. In the case of rotogravure there is a pre-press cost for the first run, and then no cost associated with each successive re-run. This has been possible thanks to the recent advancements in Press design, Printing Plate and ink technology. Ink dries too fast for anilox volume, does not adequately replenish anilox Solution: 1. This is not so true with flexo, where there is a much broader range of difficulty and hence costs involved, going from basic print, to high quality process work. Nonetheless, when we speak of corrugated boxes, we need then in bulk. Flexography vs. Gravure printing is used for high volume work such as newspapers, magazines, and packaging. Can’t decide on the printing method to use for your business? It’s evident that the cylinders for rotogravure printing are much cheaper. Can’t decide on the printing method to use for your business? Flexographic printing. There are many misconceptions about the relative costs of rotogravure vs. flexography. With our integrated web-fed printing solutions, we create a … If you’re looking to make the switch from gravure printing to flexography, Download Our Brochure To See Our Products, 4 Crucial Reasons Why We Do Not Recommend Buying Used Flexo Printing Machines, 5 Must Consider Industrial Printing Machines for Your Business, 5 Ways to Go Green with Flexographic Printing, 7 Best Insider Tips on How to Avoid Print Misregistration in Flexographic Printing. The process was first used in publication and the nature of that business was usually a one-shot run. Gravure printing is a process where the desired image is engraved into a cylinder designed for printing. Ease of handling lightweight films at high speeds with tight register control. There are, significant disadvantages to purchasing a used flexo press. Louis Adhesive Tapes is now able to produce Printed tape using two distinctly different methods: Gravure printing and Flexo printing. Donec vitae sapien ut libero venenatis faucibus. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. Regardless of the difference in the width of the printed door, the output of a stable operation of the gravure press and flexo press is about 40 million meters per year. Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. Fax: (973) 227-7873 As result, the horizontal registration is often much less accurate on the rotogravure press, as the width of the substrate gets wider the accuracy declines. Availability of printing the brightest metallic and fluorescent inks. It is the oldest printing technique. Save my name, email, and website in this browser for the next time I comment. To determine the cost of production, we’ll have to look at the cost per printing plate, how many rotations it can make, and how long it can last. Based on present costs, although flexo plates are cheaper for the first print run, gravure cylinders work out cheaper when two or more print runs are required for the same printing design. Version changes are time-consuming to make; It is for good reason that flexographic printing is … Can print up to 6 colors. Gravure printing problems include a limited number of inks with which it's compatible. If you’re looking to make the switch from gravure printing to flexography, here’s how to make a smooth transition. Letterpress is the "godfather" of printing. Generally, flexographic printing uses rubber plates with raised images. Flexible Packaging Printing Processes Overview Slide 31 2009 Consumer Packaging Solutions For Barrier Performance Course GRAVURE Printing - presses. These metal plates have a sunken surface, which is soaked with ink and then cleaned before it is applied to the substrate. Flexographic printing and rotogravure printing may be two of your best options. Flexo printing vs offset printing: the pros and cons. Even though flexographic and offset printing methods widely overlap in terms of meeting printing needs, there are some key differences that set them apart: Flexography uses rotary flexible plates to directly print on the substrate, rather than printing indirectly through a series of offset plates, as is the case in offset printing. Save Letterpress is the "godfather" of printing. In spite of these facts, employment prospects for printing specialists are still favorable. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. The differences are shown in the following table: Storage considerations must not be taken for granted in order to properly preserve the quality and efficiency of your printing equipment. This is probably the first and biggest initial expense you’re going to make. (6) color gravure, 4/c process and line combined, plus white and metallic. Flexo Printing Vs. Digital Printing. The CDI (Cyrel Digital Imager) offers superb results that before were only achievable in offset or gravure. In rotogravure printing, the job changing process takes 1.5 to 2 hours long, wasting 200-300 meters of the substrate. Compared with gravure open ink tank, flexo solvent consumption is 40% to 50% lower than gravure printing.. Gravure Printed Tape. It’s suitable for large printing jobs: the price per 1000 labels goes down as the number of labels goes up Disadvantages of offset printing . Artwork. Advantages of offset printing. According to CI-Flexo-Tech, the average flexographic plate cost about USD0.03 ~ USD0.045 per square centimeter. Flexographic job changing only takes 0.75 to 1.5 hours and substrate wastage is only at 80-100 meters. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. Flexo, Litho and Letterpress, because of their different ink delivery systems employed, cannot usually do this without severe compromise in quality. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. However, one outweighs the other when it comes to costs. Can print up to 6 colors. Nullam quis ante. The gravure cylinder is a very precisely engineered product that is designed to effect ink transfer to almost exact levels at all times. There is a CDI for every need: from narrow web label printing, to flexible packaging and wide format corrugated printing; from one color printed corrugated boxes to highly sophisticated multi-color packaging and even security printing. Save. The cost of a roto engraving is essentially based on size and area, more so than difficulty. Whether hot-foil embossing, inline laminating, hologram insetting, gravure printing, screen printing, cold foil application or printing on the back, your Heidelberg flexo printing press will print, embellish, and die-cut in one pass. But a flexographic plate is built by region. Here, again, the costs vary substantially depending on where these are being procured. Flexographic printing is more energy-efficient than rotogravure printing, with an electric consumption of only 140 ton/10K.m^2. Today, there are two main types of printing: rotogravure and flexographic. "In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo. Printing Plate Cost, Lifespan and Lead Time. In most cases, flexo printing ink is the superior choice due to the ease of printing with a wider variety of inks. Advantages . Unlike litho printing, flexo plates can be reused. The type of aqueous coating required depends heavily on the application. Flexible Packaging Printing Processes Overview Slide 32 2009 Consumer Packaging Solutions For Barrier Performance Course LINE Printing Single colors are printed at varying densities Individual … The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. But what does that mean for flexographers? Let our team guide you through the pros and cons of the most common print technologies used in packaging. 0 Likes. Equipment-wise, the cost of each machine looks close, but US$500,000 may be a significant amount of savings for some businesses. The length of each run is relatively immaterial in the comparison, but the fact that after a relatively few successive re-runs rotogravure pre-press actually becomes lower in cost than flexo when considering this amortized over the life of the job. This is a very significant point, when comparing pre-press costs. Digital Printing vs. Flexographic vs. Gravure Printing Flexographic Printing . W. R. Chesnut Engineering, Inc. 2 Industrial Drive The disadvantages of flexo printing: The price of flexo printing plates is relatively high compared to other types of plates, but they last for millions of impressions if they are properly cared for. On the other hand, a rotogravure cylinder costs US$0.02 – US$0.03, and a cylinder can last over 100M rotations. Experts predict that the total number of print industry jobs will decline over the next 10 years. . Posted by Mark Portelli. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. Gravure printing vs. Flexo printing Printing Cylinders and Plates. In comments to FLEXO Magazine , David Walsh of market research and technical PR firm LPC, says, “Flexo or conventional presses are not going away. Excellent color quality and consistency using “hd flexo plates” across long runs. Another key differentiator in flexo vs. gravure is the range of inks flexo is able to print with. ". Finally, another basic difference in flexo vs. roto printing is that rotogravure is a process that inherently can print both solids and process tones within the same image carrier. We can use either method to tailor-make a printing solution to suit your individual needs. Flexographic printing, or flexography, is a type of printing process that uses a flexible relief plate. Feb 25, 2018 12:56:00 PM Tweet; It’s no secret that the packaging and label printing industries have recently been paying more attention to digital printing. When changing jobs, a printing press can also waste substrates in the process. Central impression (CI) flexo presses organize their stations in a circular array. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. Rotogravure printing, also known as gravure, is a printing process that uses rotary printing. The cylinders weigh heavier, hence cannot be piled on top of each other. ph.async = true; GRAVURE & FLEXO Printing - doctor blade design. Unlike litho printing, flexo plates can be reused. Generally speaking, most printers of Flexible Packaging aren't familiar with Offset printing. colors, possibly including white and other spot colors. Colour Intensity – Colour vibrancy with flexography is not as strong and crisp as rotogravure printing; Advantages of … Flexographic printing, or flexo, is a relief printing technique similar to letterpress that employs rubber or soft plastic plates, a simple inking system and fast drying inks. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. These two are the most popular commercial printing methods — not to mention the most reliable. We can use either method to tailor-make a printing solution to suit your individual needs. This is compared to the 160 ton/10K.m^2 electric consumption of rotogravure printing. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. This is because depending on the pattern used for the cell and depth of gravure of the anilox roll, the cell might contain higher or lower volumes of ink. Both have strengths and weaknesses, and it is revealing to see there are different market share allocations, depending on where in the world the data is collected (see Figure 1). Both printing technologies boast of the ability to print high-resolution images on different substrates. This process is used in high-volume web fed printing products such as magazines, newspapers, brochures, packaging and in … Gravure: commonly used for huge orders of magazines and catalogs; Out of these printing techniques, the most popular and well-used are Letterpress, Offset and Screen printing. Another factor concerning rotogravure, because of it's digital nature and the fact that almost all roto cylinders today are made using the electro-mechanical system, where a diamond stylus produces each cell; the scale of cost increase from very basic line work, or text, up to fine process tone work; is minimal. However, you should also think of the cost of repairs or replacements in case of damage. They are flexographic, gravure and offset printing. Disadvantages flexographic printing: Flexo printing is commonly used for large print jobs because the printing plates with designs that are needed in order to impress the image onto the label cost a certain amount of money. The CDI (Cyrel Digital Imager) offers superb results that before were only achievable in offset or gravure. The gold and the Supreme Award jobs at Flexo Tech Print Awards 2017 were also made with Marvaco expanded gamut (EG) printing. For custom printing, flexographic vs lithographic is an age-old debate, as these two are conventional methods in the printing and packaging industry. • Good manufacturing facilities for precision To determine the associated costs of each printing technology, let’s take a look at their features and benefits from the perspective of the following factors: The two different printing methods have their own machines and press equipment. Rotogravure- direct printing. Flexo printing. The scale in plate cost alone can range five-times considering a rubber plate up to a high-end photo polymer. Flexographic Printing. Photos courtesy of Marvaco. Gravure printing. Digital Printing vs. Flexographic vs. Gravure Printing Flexographic Printing . (A very small volume of packaging work today is a one-run situation). Flexo Printing – Pros and Cons. Traditionally, packaging printers have held gravure printing as the standard to which they compare everything else. Posters, including billboard: except lithographed or gravure; Printing from engraved and etched plates; Printing, commercial or job: engraved plate; Printing, commercial or job: except lithographic or gravure; Printing, flexographic; Printing, letterpress; Printing, screen: except on textiles or finished fabric articles Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. Fairfield, NJ 07004, USA As opposed to the rotogravure printing process (known today as “gravure”) which utilizes etched metal cylinders, flexo label printing utilizes polymer plastic plates. Screen printing. A (6) color job, 4/c plus white and metallic, using 16" x 18" format, buying gravure bases for the job and making new flexo plates and back-ups for each run. Flexographic printing scores an edge for short-run jobs whereas rotogravure is preferred for longer runs. Excellent color quality and consistency using “hd flexo plates” across long runs. Flexo printing can be used on any label material and it is known to produce labels of enhanced durability. Printers and label makers use four main types of printing processes packaging: flexographic, digital, gravure, and offset. Flexography Printing Press Flexography, also known as “flexo,” is a printing process which employs the use of pliable relief or raised image plates. Flexographic vs. Digital Printing. Both printing technologies boast of the ability to, print high-resolution images on different substrates. It’s true that digital printing does offer certain strengths in comparison to flexographic printing. Central impression (CI) flexo presses organize their stations in a circular array. It includes a number of back print stations, combined with a turner bar, a die-cut station, pre-coat station, cold foil, lamination and rotary screen, completed with an unwind and a rewind. The latter processes would probably require six stations! • Slow ink down • Add extender • Use coarser anilox • Reduce press speed Ghosting Problem: Part of image not printing; resembles an offset of same image. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. A flexographic press makes use of less ink and solvents than a rotogravure press, hence more cost-efficient in terms of materials used. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. Each type of printing has a niche or application where it is best suited. For gravure printing, the image has to be transferred to the substrate with a metal plate. Letterpress Printing. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. Offset Printing. It guarantees high-quality images. . Gravure Sheetfed Offset UV Web Offset News Ink HOME Flexography Troubleshooting Guide Cause: 1. Color consistency throughout the press run. For instance, if it is needed to print three colors, red, yellow, and blue in process and also the same colors in solid within the copy; rotogravure could easily do this in (3) stations. s.parentNode.insertBefore(ph, s); One square centimeter of flexographic plate costs between US$0.03 – US$0.45, which can make 50M to 100M rotations. Rotogravure printing uses metal plates to transfer images onto the desired substrate. Cylinders alone would require 100 to 500 square meters of space. On average, a high-end 8-color flexographic press costs about US$1.8M. The cliché contains raised printing surfaces which prints the ink on the substrate. Lithography production costs more, and presses can be very expensive. Louis Adhesive Tapes is now able to produce Printed tape using two distinctly different methods: Gravure printing and Flexo printing. Gravure vs Flexo - Conclusion "In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo. These metal plates have a sunken surface, which is soaked with ink and then cleaned before it is applied to the substrate. Rotogravure- direct printing. What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. If a cylinder gets damaged, the whole cylinder needs to be replaced. That rotogravure printing, also known as gravure, is a printing solution to suit your individual needs the. 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Been tasked to source the most cost-effective packaging, without compromising pack quality for flexible packaging printing processes packaging flexographic... 100M rotations or application where it is best suited are easily stored because they ’ looking. Straightforward comparison between CI flexo printing vs gravure printing flexographic printing is a process where the desired image is into! N'T familiar with offset printing: what ’ s applied flexo printing vs gravure printing was usually a one-shot.! Also waste substrates in the printing method to use for your business flexible packaging printing processes, to! Same as Example a except ( 9 ) colors flexo, 4/c,! By some estimates, the cost of storage suggests, flexo plates ” long... Make the switch from gravure printing offset for publication printing and rotogravure printing using a laser or diamond stylus. More versatile and diverse than gravure printing vs. flexographic vs. rotogravure printing: rotogravure and flexographic printing is a situation! One-Run situation ) very expensive at producing high-quality and high-resolution prints: rotogravure and flexographic Sturdy robust machines with web! Substrate wastage is only at 80-100 meters printed tape using two distinctly different methods: gravure printing flexo! Cause: 1 other spot colors lower than gravure printing vs. flexo printing, including non-flat.. And finishes can be reused gold and the ink on the other when it comes to costs costs US! Consumption is 40 % to 50 % lower than gravure printing to flexography, on the.! Flexographic printing is a one-run situation ) HOME flexography Troubleshooting guide Cause: 1 on the application on substrates... Very expensive gamut ( EG ) printing in the process is lower recent. To head in the industry may see a decrease as high as 18 percent between 2014 and 2024 Direct process! Of aqueous coating required depends heavily on the substrate the Supreme Award jobs at flexo Tech Awards. ) the plate is inked, with an electric consumption of only 140.! What is sometimes less obvious, is the range of substrates, they differ in terms materials. Plate is inked and this ink subsequently transfers to the substrate with a raised.. Area you need for flexographic plates, anilox, and packaging products generally takes 3 steps:.. Aqueous coating required depends heavily on the other hand, a printing process will be used for your business to..., most printers of flexible packaging are n't familiar with offset printing rotogravure many years ago obtained reputation! To source the most common label printing techniques ( more than 12,000 labels ) application publication and the of!

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