Gravure (Rotogravure) printing uses engraved cells on a metal cylinder to carry ink. Excess ink is wiped off by a doctor blade, and the ink held in the recessed cells transfers to the substrate under pressure. With high speed, stable color, and excellent repeatability, gravure is a top choice for flexible packaging films (BOPP/BOPE, PET, NY), metallized films, aluminum foil, coated paper, and premium paper laminates—especially on long runs.
Core Strengths
Built for speed: Runs fast on wide webs; can be integrated in-line with coating, varnish, cold/hot foil, lamination, and slitting.
Rich, even color: Cell volume controls ink laydown for smooth solid areas, gradients, skin tones, and metallic effects.
Wide substrate window: Handles low–surface-energy films and foils more easily than many processes.
Tight register: Keeps continuous patterns and metallic/laser effects aligned at speed.
Long plate life: Cylinders last; repeat orders match color more easily.
Why Gravure Shines on High-Volume Packaging
Unit cost drops as volumes rise
Cylinders cost more up front, but on long runs the cost is quickly amortized. High productivity + low waste = better economics for big jobs.
Color consistency you can repeat
Using the same cylinders and ink curves across plants/regions helps achieve minimal color drift on reorders.
Large solids & high coverage look cleaner
Big brand panels, deep backgrounds, metallic fields, and smooth gradients print without banding or mottle.
In-line efficiency
Common to run gravure + coating/varnish/lamination in one pass, tightening lead time and yield.
Film-first performance
On BOPP/PET/NY/foil/metallized structures, gravure ink transfer and adhesion are reliably strong and lamination-friendly.
Typical Applications
Food & personal care flexibles: snack bags, confectionery wraps, coffee/portion packs, pet food, detergent pods film.
Premium paper/film laminates for spirits & gift boxes: metallic bases, fine patterns, subtle gradients.
Shrink sleeves: saturated graphics on curved surfaces.
Foil & retort structures: durable colors for heat/retort conditions.
Continuous patterns: décor wallpapers and large-background designs.
Quick Comparisons (Selection Guide)
- Flexo:Flexo is agile for short runs; gravure is more economical on long runsand often smoother for solids/gradients/metallics, especially on films.
- Offset:Offset excels on paper detail; gravure leads on films, large solids, metallic bases, and in-line speed.
- Digital:Digital is plate-free and fast for short runs & mockups; gravure wins on very long runsfor cost and durability.