The difference between flexo and gravure printing

Flexo (flexographic printing) and gravure (gravure printing) are two common printing processes. Their main differences are as follows:

1. Different Printing Plate Characteristics

- Flexo: Flexographic printing uses a flexible plate (such as a rubber or photopolymer plate). The image area on the plate surface is raised dots or lines, while the non-image area is flat, similar to the principle of a stamp.

- Gravure: A metal gravure plate (usually copper, etched or engraved) is used. The image area is recessed dots or grooves, while the non-image area is flat.

2. Different Ink Transfer Methods

- Flexographic printing uses an anilox roller to transfer ink in a metered manner. The ink is relatively thin (mostly water-based or UV ink), has strong adhesion, and is environmentally friendly.

- Gravure: Ink first fills the recessed areas of the plate, then a doctor blade removes excess ink from the plate surface, leaving only the ink in the recessed areas for transfer to the substrate. The ink is thicker (mostly solvent-based) and has high color saturation.

3. Different Application Scenarios

- Flexo: Suitable for high-volume, low-cost printing, such as food packaging (plastic bags, paper boxes), labels, newspapers, etc., and particularly excels at printing on non-smooth surfaces (such as paper and cardboard).

- Gravure: Suitable for applications requiring high color reproduction and fineness, such as plastic film (beverage bottle packaging), posters, and high-end packaging. It can achieve rich color gradations and large-scale solid printing.

4. Cost and Efficiency

- Flexo: Low plate production cost, short cycle time, and simple equipment maintenance make it suitable for small and medium-sized production runs and highly efficient.

- Gravure: High plate production cost, long cycle time (complex engraving/etching processes), and large equipment investment are required, but it is suitable for large-scale continuous production, and unit costs decrease as output increases.