flexo printing vs gravure printing

Gravure Printed Tape. Availability of printing the brightest metallic and fluorescent inks. Lithography production costs more, and presses can be very expensive. Rotogravure printing uses metal plates to transfer images onto the desired substrate. The only difference is the versatility of use and cost of production. 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. In evaluating the two examples, it's evident that in "Example A" the cost of flexo vs. rotogravure is equal after two production runs. 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 . Gravure printing. Excellent color quality and consistency using “hd flexo plates” across long runs. The ability to create reverse printed laminated labels in-line. The high efficiencies associated with low cost gravure inks and high running speeds. Digital Printing vs. Flexographic Printing. • 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 most cases, flexo printing ink is the superior choice due to the ease of printing with a wider variety of inks. Unlike litho printing, flexo plates can be reused. Luckily, flexographic printing materials are easily stored because they’re made of lightweight and flexible materials like elastomer and photopolymer. Flexible Packaging Printing Processes Overview Slide 31 2009 Consumer Packaging Solutions For Barrier Performance Course GRAVURE Printing - presses. We can use either method to tailor-make a printing solution to suit your individual needs. In comments to FLEXO Magazine , David Walsh of market research and technical PR firm LPC, says, “Flexo or conventional presses are not going away. 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. Printers and label makers use four main types of printing processes packaging: flexographic, digital, gravure, and offset. Flexo Printing – Pros and Cons. Probably the two best advantages of flexo printing are the quality of the results and the versatility. Flexography, on the other hand, uses a rubber plate with a raised surface. 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. 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. Advantage gravure. 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. In rotogravure printing, the job changing process takes 1.5 to 2 hours long, wasting 200-300 meters of the substrate. This is compared to the 160 ton/10K.m^2 electric consumption of rotogravure printing. Generally, flexographic printing uses rubber plates with raised images. These metal plates have a sunken surface, which is soaked with ink and then cleaned before it is applied to the substrate. Artwork. This is probably the first and biggest initial expense you’re going to make. So should one get damaged, you can save on costs by only purchasing a replacement for the damaged region. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure 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). Color consistency throughout the press run. Fairfield, NJ 07004, USA When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. W. R. Chesnut Engineering, Inc. 2 Industrial Drive Flexo, Litho and Letterpress, because of their different ink delivery systems employed, cannot usually do this without severe compromise in quality. According to CI-Flexo-Tech, the average flexographic plate cost about USD0.03 ~ USD0.045 per square centimeter. One square centimeter of flexographic plate costs between US$0.03 – US$0.45, which can make 50M to 100M rotations. The gravure cylinder is a very precisely engineered product that is designed to effect ink transfer to almost exact levels at all times. Gravure presses have individual print stations arrayed linearly. Flexographic printing. Aside from the pre-press costs, printers should also consider some of the other advantages of rotogravure: Dick Chesnut On the other hand, a rotogravure press of the same class costs about US$2.3M. 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. Flexographic printing and rotogravure printing may be two of your best options. These plates are flexible photopolymers that are positioned around web press cylinders that rotate. Screen printing. The CDI (Cyrel Digital Imager) offers superb results that before were only achievable in offset or gravure. 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. ". Letterpress printing: the process explained. Read on to know what’s right for your budget. It’s got a sunken surface where ink is applied and then wiped off before it’s applied. A flexographic printing press runs faster than a rotogravure press. As opposed to the rotogravure printing process (known today as “gravure”) which utilizes etched metal cylinders, flexo label printing utilizes polymer plastic plates. Let our team guide you through the pros and cons of the most common print technologies used in packaging. Advice on Finding Your Next Job in the Printing Industry. Rotogravure printing uses metal plates to transfer images onto the desired substrate. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. The production process also costs much less. An imager for every need: from CDI Spark to CDI Crystal. Equipment-wise, the cost of each machine looks close, but US$500,000 may be a significant amount of savings for some businesses. 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. 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 . 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. Gravure printing problems include a limited number of inks with which it's compatible. … This is the image carrier and contains all the text or images which eventually get printed on the substrate. As the name suggests, flexo printing utilises flexible plates for a rotary printing process. Here we have identified the key similarities and differences between rotogravure and flexographic printing to help you out. 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. The average storage area you need for flexographic plates, anilox, and sleeves is 200 square meters. 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 … Gravure Printed Tape . Flexo Printing Process vs. Rotogravure. It’s more versatile and diverse than gravure printing. There are significant disadvantages to purchasing a used flexo press. When changing jobs, a printing press can also waste substrates in the process. Flexography vs. 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. 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. By some estimates, the industry may see a decrease as high as 18 percent between 2014 and 2024. 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. Offset Printing. Here are some helpful ways to distinguish which printing process will be used for your next order. 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. Unlike litho printing, flexo plates can be reused. Today, there are two main types of printing: rotogravure and flexographic. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. But a flexographic plate is built by region. The latter processes would probably require six stations! Printing-press cost works out to be considerably higher in rotogravure printing as compared to flexographic printing. This has been possible thanks to the recent advancements in Press design, Printing Plate and ink technology. Copper plated steel cylinders are engraved with the chosen design using a laser or diamond tipped stylus. Disadvantages. Generally, flexographic printing uses rubber plates with raised images. Digital printing is a complementary process to flexographic printing — the two can happily co-exist side-by-side. However, one outweighs the other when it comes to costs. On the other hand, a rotogravure cylinder costs US$0.02 – US$0.03, and a cylinder can last over 100M rotations. colors, possibly including white and other spot colors. Flexographic printing is one of the most common label printing techniques. (A very small volume of packaging work today is a one-run situation). Phone: (973) 227-6995 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. Email: [email protected], 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. 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. Lithography is used for anything that needs vibrant colours and is … This process is used in high-volume web fed printing products such as magazines, newspapers, brochures, packaging and in … Flexo – Indirect 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. Letterpress Printing. Louis Adhesive Tapes is now able to produce Printed tape using two distinctly different methods: Gravure printing and Flexo printing. 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. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. Print quality . Nonetheless, when we speak of corrugated boxes, we need then in bulk. Posted by Mark Portelli. 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. "In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo. They are flexographic, gravure and offset printing. Central impression (CI) flexo presses organize their stations in a circular array. Flexographic printing, or flexography, is a type of printing process that uses a flexible relief plate. In the case of flexo, there are pre-press costs associated with each run, as the following examples will show. Easily attainable and repeatable process printing. What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. Can’t decide on the printing method to use for your business? Gravure printing is used for high volume work such as newspapers, magazines, and packaging. Read on as we discuss the differences between these techniques and figure out why they are the most popular in the industry. These metal plates have a sunken surface, which is soaked with ink and then cleaned before it is applied to the substrate. Printing Plate Cost, Lifespan and Lead Time. The cost of a roto engraving is essentially based on size and area, more so than difficulty. Flexo – Indirect printing. Both printing technologies boast of the ability to, print high-resolution images on different substrates. There are, significant disadvantages to purchasing a used flexo press. Though these two have the ability to print high-quality images on a vast array of substrates, they differ in terms of production cost. The team typically replies in a few minutes. Excellent color quality and consistency using “hd flexo plates” across long runs. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. . Two technologies that are often compared are letterpress and flexo printing. Flexo printing vs offset printing: the pros and cons. The cost of storage investment would be higher for the rotogravure process than the flexographic process. Gravure printing vs. Flexo printing Printing Cylinders and Plates. Lithography production costs more, and presses can be very expensive. 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. In the case of "Example B", the break-even point is reached after just the first production run. The gold and the Supreme Award jobs at Flexo Tech Print Awards 2017 were also made with Marvaco expanded gamut (EG) 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. The cliché contains raised printing surfaces which prints the ink on the substrate. But flexographic printing is more efficient for longer production runs, having fast lead times, fewer ink costs, and reduced energy consumption. Letterpress is the "godfather" of printing. • Direct printing process gave the best print quality. Worth noting as well is that rotogravure printing is better for shorter runs because the cost of the cylinders is lower. For gravure printing, the image has to be transferred to the substrate with a metal plate. Producing these products generally takes 3 steps: 1. Can’t decide on the printing method to use for your business? Package printing comes in many shapes and sizes. The plate is inked, with the inked image being moved to the printing surface afterwards. Read on to know what’s right for your budget. Ease of handling lightweight films at high speeds with tight register control. Donec vitae sapien ut libero venenatis faucibus. Save. For custom printing, flexographic vs lithographic is an age-old debate, as these two are conventional methods in the printing and packaging industry. 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. 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 job changing only takes 0.75 to 1.5 hours and substrate wastage is only at 80-100 meters. Flexography, on the other hand, uses a rubber plate with a raised surface. Ink dries too fast for anilox volume, does not adequately replenish anilox Solution: 1. It is the oldest printing technique. The latter only has a 120-200 meters per minute running capacity. Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. })(document, 'script', '//demo.citrus.ph/?p=134&ph_apikey=42de92a5dd4ac09fe15ae8f8c85302a6'); Copyright Lead Yuan Flexo 2019 | Powered by: Citrus.ph, Hi! Flexographic vs. Digital Printing. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. President Flexographic printing scores an edge for short-run jobs whereas rotogravure is preferred for longer runs. Flexo printing. . 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.

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