As the name suggests, flexo printing utilises flexible plates for a rotary printing process. Generally speaking, most printers of Flexible Packaging aren't familiar with Offset printing. with a lot of local manufacturers of printing presses. Save. Gravure printing vs. Flexo printing Printing Cylinders and Plates. Flexo printing can be used on any label material and it is known to produce labels of enhanced durability. But that’s just the appropriate response! 0 Likes. Advantages . Printers and label makers use four main types of printing processes packaging: flexographic, digital, gravure, and offset. Flexo – Indirect printing. Excellent color quality and consistency using “hd flexo plates” across long runs. Gravure Sheetfed Offset UV Web Offset News Ink HOME Flexography Troubleshooting Guide Cause: 1. These metal plates have a sunken surface, which is soaked with ink and then cleaned before it is applied to the substrate. 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. . Luckily, flexographic printing materials are easily stored because they’re made of lightweight and flexible materials like elastomer and photopolymer. Two technologies that are often compared are letterpress and flexo printing. Rotogravure printing uses metal plates to transfer images onto the desired substrate. Save my name, email, and website in this browser for the next time I comment. Digital Printing vs. Flexographic vs. Gravure Printing Flexographic Printing . Here are some helpful ways to distinguish which printing process will be used for your next order. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. Reading Time: 3 minutes So, you’ve been tasked to source the most cost-effective packaging, without compromising pack quality. The following study uses data obtained from several trade houses that specialize in roto and flexo plate making as well as information obtained from printers that do their own flexo pre-press. In the case of flexo, there are pre-press costs associated with each run, as the following examples will show. 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. Ease of handling lightweight films at high speeds with tight register control. Version changes are time-consuming to make; It is for good reason that flexographic printing is … There are many misconceptions about the relative costs of rotogravure vs. flexography. With flexographic printing, the image to be printed is rested on a rubber-based printing plate. ". But what does that mean for flexographers? This process is used in high-volume web fed printing products such as magazines, newspapers, brochures, packaging and in … This has been possible thanks to the recent advancements in Press design, Printing Plate and ink technology. Gravure is gradually losing market share to offset for publication printing and to flexo for packaging applications. 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. 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. This is compared to the 160 ton/10K.m^2 electric consumption of rotogravure printing. 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. 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. These two are the most popular commercial printing methods — not to mention the most reliable. In rotogravure printing, the job changing process takes 1.5 to 2 hours long, wasting 200-300 meters of the substrate. • Slow ink down • Add extender • Use coarser anilox • Reduce press speed Ghosting Problem: Part of image not printing; resembles an offset of same image. Excellent color quality and consistency using “hd flexo plates” across long runs. 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. Rotogravure printing materials require more thought and space in terms of storage. Screen printing. 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. The only difference is the versatility of use and cost of production. ph.type = 'text/javascript'; Package printing comes in many shapes and sizes. Central impression (CI) flexo presses organize their stations in a circular array. 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. The cylinders weigh heavier, hence cannot be piled on top of each other. Can’t decide on the printing method to use for your business? Nullam quis ante. Flexographic printing vs gravure printing what’s the difference? Flexible Packaging Printing Processes Overview Slide 31 2009 Consumer Packaging Solutions For Barrier Performance Course GRAVURE Printing - presses. Equipment-wise, the cost of each machine looks close, but US$500,000 may be a significant amount of savings for some businesses. Flexography Printing Press Flexography, also known as “flexo,” is a printing process which employs the use of pliable relief or raised image plates. Rotogravure printing uses metal plates to transfer images onto the desired substrate. See the full range of CDI Spark and CDI Crystal imagers The cost of storage investment would be higher for the rotogravure process than the flexographic process. Easily attainable and repeatable process printing. Flexographic Printing. 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. 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. Can’t decide on the printing method to use for your business? Letterpress printing: the process explained. 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. Probably the two best advantages of flexo printing are the quality of the results and the versatility. So should one get damaged, you can save on costs by only purchasing a replacement for the damaged region. This printing technique allows a lot of flexibility with label material. For instance: Rotogravure many years ago obtained a reputation for being a high cost process from the publication industry. Printing-press cost works out to be considerably higher in rotogravure printing as compared to flexographic printing. Flexographic vs. Rotogravure Printing: What’s Right For You and Your Budget? Both commercial printing methods are great at producing high-quality and high-resolution prints. The gravure cylinder is a very precisely engineered product that is designed to effect ink transfer to almost exact levels at all times. According to CI-Flexo-Tech, the average flexographic plate cost about USD0.03 ~ USD0.045 per square centimeter. A flexographic printing press runs faster than a rotogravure press. Aside from the pre-press costs, printers should also consider some of the other advantages of rotogravure: Dick Chesnut Two technologies that are often compared are letterpress and flexo printing. It is a straightforward comparison between CI flexo printing and rotogravure printing using a conventional stack press for flexible packaging films and laminates. The type of aqueous coating required depends heavily on the application. 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. Digital Printing vs. Flexographic vs. Gravure Printing Flexographic Printing . colors, possibly including white and other spot colors. Though these two have the ability to print high-quality images on a vast array of substrates, they differ in terms of production cost. Flexographic printing works on a wider range of substrates, including non-flat media. Flexo printing is most commonly associated with uses in flexible packaging and labels, utilizing a variety of substrates including film, paper, foil and non-woven. 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. Though these two have the ability to print high-quality images on a vast array of substrates, they differ in terms of production cost. Both printing technologies boast of the ability to, print high-resolution images on different substrates. The high efficiencies associated with low cost gravure inks and high running speeds. (6) color gravure, 4/c process and line combined, plus white and metallic. As opposed to the rotogravure printing process (known today as “gravure”) which utilizes etched metal cylinders, flexo label printing utilizes polymer plastic plates. Flexo printing vs offset printing: the pros and cons. Colour Intensity – Colour vibrancy with flexography is not as strong and crisp as rotogravure printing; Advantages of … Very high speed capability makes flexo printing more efficient for the big jobs. The production process also costs much less. 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. 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. Each type of printing has a niche or application where it is best suited. In-RIP trapping moves the trapping to the Raster image processor (RIP) trapping at the last moment. Flexo Printing – Pros and Cons. Flexography, on the other hand, uses a rubber plate with a raised surface. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. However, you should also think of the cost of repairs or replacements in case of damage. Trying to find the perfect format, features, materials and finishes can be a headache. Flexographic printing and rotogravure printing may be two of your best options. In most cases, flexo printing ink is the superior choice due to the ease of printing with a wider variety of inks. On average, a high-end 8-color flexographic press costs about US$1.8M. Printing Plate Cost, Lifespan and Lead Time. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. Color consistency throughout the press run. The differences between the two methods are outlined below. Letterpress is the "godfather" of printing. Offset Printing. In this process, ink is applied to a relief plate cylinder, which then prints the relief design onto the label material. Same as Example A except (9) colors flexo, 4/c process, 3/c line, plus white and metallic. Click one of our member below to chat on. • Direct printing process gave the best print quality. For custom printing, flexographic vs lithographic is an age-old debate, as these two are conventional methods in the printing and packaging industry. Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. Gravure and flexographic printing are essentially in-line processes. In spite of these facts, employment prospects for printing specialists are still favorable. The former can run at 300-500 meters per minute. Advice on Finding Your Next Job in the Printing Industry. Two of the most popular printing processes are flexographic and offset printing. With our integrated web-fed printing solutions, we create a simple workflow within your print shop. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. The ability to create reverse printed laminated labels in-line. … Etiam sit amet orci eget eros faucibus tincidunt. The differences between the two methods are outlined below. Flexo Printing Process vs. Rotogravure. Compared with gravure open ink tank, flexo solvent consumption is 40% to 50% lower than gravure printing.. The latter processes would probably require six stations! Gravure Printed Tape. Read on as we discuss the differences between these techniques and figure out why they are the most popular in the industry. 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. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. On the other hand, a rotogravure press of the same class costs about US$2.3M. These plates are flexible photopolymers that are positioned around web press cylinders that rotate. Read on to know what’s right for your budget. Equipment-wise, the cost of each machine looks close, but US$500,000 may be a significant amount of savings for some businesses. Can print up to 6 colors. Worth noting is that you should be leaning to brand new machines instead of used ones. Flexographic printing and rotogravure printing may be two of your best options. Both commercial printing methods are great at producing high-quality and high-resolution prints. They are flexographic, gravure and offset printing. 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. Producing these products generally takes 3 steps: 1. The CDI (Cyrel Digital Imager) offers superb results that before were only achievable in offset or gravure. There are, significant disadvantages to purchasing a used flexo press. There are significant disadvantages to purchasing a used flexo press. To produce an impression, letterpress printers had to construct individual letters and characters into a "forme", secure them into a … Flexographic job changing only takes 0.75 to 1.5 hours and substrate wastage is only at 80-100 meters. Flexographic vs. Digital Printing. 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. 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. Fax: (973) 227-7873 Flexographic printing, or flexography, is a type of printing process that uses a flexible relief plate. The plate is inked, with the inked image being moved to the printing surface afterwards. Flexographic printing. The team typically replies in a few minutes. It’s got a sunken surface where ink is applied and then wiped off before it’s applied. Gravure and flexo, two primary printing processes, continue to compete head to head in the packaging market segment. Gravure printing is a process where the desired image is engraved into a cylinder designed for printing. This enables you to pile them on top of each other for easy and safe storage while saving on space and shelving. Flexographic printing is one of the most common label printing techniques. Flexographic printing scores an edge for short-run jobs whereas rotogravure is preferred for longer runs. Fairfield, NJ 07004, USA Let our team guide you through the pros and cons of the most common print technologies used in packaging. We are one of the world’s leading supplier of equipment and services to packaging and label manufacturers in the folding carton, corrugated board and flexible materials industries. Central impression (CI) flexo presses organize their stations in a circular array. Digital Printing vs. Flexographic Printing. By some estimates, the industry may see a decrease as high as 18 percent between 2014 and 2024. Flexography vs. It attempts to illustrate by practical example the cost differences that can be anticipated when considering a narrow-web press situation doing high-end tone printing.sidering this amortized over the life of the job. "In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo. If deciding to use custom labels for marketing, you may already know that there are a number of different printing options available. Posted by Mark Portelli. The average storage area you need for flexographic plates, anilox, and sleeves is 200 square meters. 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. • Good manufacturing facilities for precision 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. Flexo printing. It’s more versatile and diverse than gravure printing. Letterpress Printing. Rotogravure printing, also known as gravure, is a printing process that uses rotary printing. 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). These two are the most popular commercial printing methods — not to mention the most reliable. Nonetheless, when we speak of corrugated boxes, we need then in bulk. Today, there are two main types of printing: rotogravure and flexographic. })(document, 'script', '//demo.citrus.ph/?p=134&ph_apikey=42de92a5dd4ac09fe15ae8f8c85302a6'); Copyright Lead Yuan Flexo 2019 | Powered by: Citrus.ph, Hi! Flexographic printing is more energy-efficient than rotogravure printing, with an electric consumption of only 140 ton/10K.m^2. W. R. Chesnut Engineering, Inc. 2 Industrial Drive Rotogravure- direct printing. 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 . The only difference is the versatility of use and cost of production. When changing jobs, a printing press can also waste substrates in the process. Artwork. Digital printing is a complementary process to flexographic printing — the two can happily co-exist side-by-side. One square centimeter of flexographic plate costs between US$0.03 – US$0.45, which can make 50M to 100M rotations. Disadvantages. Unlike litho printing, flexo plates can be reused. The substrates on the rotogravure press go through on average 4~6 meters of distance between color stations; on a flexographic press, goes through 4-6cm. The process was first used in publication and the nature of that business was usually a one-shot run. 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. Advantages of offset printing. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. 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. 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. If a cylinder gets damaged, the whole cylinder needs to be replaced. The scale in plate cost alone can range five-times considering a rubber plate up to a high-end photo polymer. Posted at 01:43h in Flexography, Printing by admin 0 Comments. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. 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. That cylinder is inked and this ink subsequently transfers to the paper. The cost of a roto engraving is essentially based on size and area, more so than difficulty. Unlike litho printing, flexo plates can be reused. This is the image carrier and contains all the text or images which eventually get printed on the substrate. Ink dries too fast for anilox volume, does not adequately replenish anilox Solution: 1. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. This setup is for a typical long run (more than 12,000 labels) application. Advantage gravure. It’s true that digital printing does offer certain strengths in comparison to flexographic printing. Print quality . However, one outweighs the other when it comes to costs. Traditionally, packaging printers have held gravure printing as the standard to which they compare everything else. Bulk printing is a tedious task and does require some level of optimization. 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. GRAVURE & FLEXO Printing - doctor blade design. What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. 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. But a flexographic plate is built by region. For gravure printing, the image has to be transferred to the substrate with a metal plate. In this method, a surface area with elevated letters is inked and hard-pressed to the top of the printing substrate to recreate a text or an image in reverse. Availability of printing the brightest metallic and fluorescent inks. On the other hand, a rotogravure cylinder costs US$0.02 – US$0.03, and a cylinder can last over 100M rotations. Cylinders alone would require 100 to 500 square meters of space. President Both printing technologies boast of the ability to print high-resolution images on different substrates. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. ph.async = true; . 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 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 . We can use either method to tailor-make a printing solution to suit your individual needs. ph.charset = 'UTF-8'; (function (d, t, g) { What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. In evaluating the two examples, it's evident that in "Example A" the cost of flexo vs. rotogravure is equal after two production runs. This is probably the first and biggest initial expense you’re going to make. Louis Adhesive Tapes is now able to produce Printed tape using two distinctly different methods: Gravure printing and Flexo printing. Here, again, the costs vary substantially depending on where these are being procured. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. Experts predict that the total number of print industry jobs will decline over the next 10 years. Digital printing is a mainstay for smaller printing jobs, but also be aware that this form of printing might not be the best option. Right after the Gutenberg Press popularized movable type back in the 15th century, letterpress had been the predominant printing technique for five centuries. However, one outweighs the other when it comes to costs. Another key differentiator in flexo vs. gravure is the range of inks flexo is able to print with. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. Flexo Printing Vs. Digital Printing. 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. A flexographic press makes use of less ink and solvents than a rotogravure press, hence more cost-efficient in terms of materials used. Advantages . It guarantees high-quality images. 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. Advantage gravure. In flexography printing (abbreviated to flexo) the plate cylinder is covered with a cliché. var ph = d.createElement(t), s = d.getElementsByTagName(t)[0]; Rotogravure printing, also known as gravure, is a printing process that uses rotary printing. Gravure presses have individual print stations arrayed linearly. 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. Donec vitae sapien ut libero venenatis faucibus. So all the raised surfaces on a cliché make the image of the run. 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. 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. Gravure printing problems include a limited number of inks with which it's compatible. In comments to FLEXO Magazine , David Walsh of market research and technical PR firm LPC, says, “Flexo or conventional presses are not going away. Flexographic printing and rotogravure printing may be two of your best options. The latter only has a 120-200 meters per minute running capacity. 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. • Direct printing process gave the best print quality. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. Disadvantages. An imager for every need: from CDI Spark to CDI Crystal. Lithography production costs more, and presses can be very expensive. Email: sales@chesnuteng.com, Add-On Coating and Printrs for Existing Presses, Priot Modules for “Drop-in” to Flexo, offer or Digital Press line, Offering GRAVURE and FLEXO STATIONS for applying inline flood and pattern coatings, New Affordable Press Line – COMPACT Series, New Products to be Displayed at Graphics of the Americas – Booth 1869.