Gravure Printing

Bring Your Packaging Designs to Life

Strong packaging does more than just protect the product. It’s a means of communicating your brand and it’s a major influence on how the customer perceives the quality of the product. Custom gravure printing is ideal for businesses looking to achieve high quality artwork with rich colors and excellent consistency on large runs.

This is achieved via engraved cylinders which transfer the ink onto the selected substrate. It’s ideal for long runs where you want to maintain print quality and keep the cost per unit under control. It’s used across the board for commercial packaging from flexible packaging films right through to paper based packaging.

How Does Gravure Printing Work?

The process starts with the artwork being prepared and the design engraved onto the printing cylinder. The cylinder has a series of tiny cells which hold the ink and transfer it to the material as the cylinder turns. A doctor blade then wipes the cylinder to remove the surplus ink and thus produce a clean, crisp impression.

In multicolor production, you generally have separate cylinders applying the individual colors in sequence. This is the method used in rotogravure printing and is the one which enables the manufacturer to produce very detailed designs at speed.

Cylinder preparation is a capital outlay. Once you’ve done it though, the cost gets spread over a very large number of units. Therefore, gravure is such an attractive proposition for a brand that has a lot of repeat orders and a significant packaging requirement.

Enjoy Vibrant Colors and Consistent Print Quality

Color accuracy is important when you’re dealing with customers who expect every package to be the same in terms of brand identity. Our gravure printing will deliver the detail in the graphics, the clarity of the text and the vibrancy of the color across the whole run.

PMS color matching is used to ensure that the brand colors are matched to the approved specifications. The right ink, correct cylinder engraving, appropriate material and press control will all have an effect on the final appearance.

High-resolution gravure printing can print fine detail, product images, gradients and custom logo printing. The end result is professional packaging which will have a consistent look from run to run.

Materials for Custom Packaging Printing

The right material has to be selected for print performance, product protection and the overall presentation. The materials available will of course vary depending on the printing equipment, the ink system and the packaging requirements.

• Plastic films: Suitable for flexible packaging, roll stock, and printed pouches.

• • Paper and paperboard: Useful for selected labels, wraps, and paper-based packaging applications.

• Foil materials: Support metallic appearances and specific barrier requirements when compatible with the printing process.

• Laminated substrates: Combine different layers to support print quality, durability, and product protection.

Packaging gravure is used extensively for flexible packaging applications. You need to check material compatibility prior to choosing the process. Gravure is not in any way the most cost effective solution for every rigid box or every short run job.

Choose Packaging Formats Fit Your Business

Different products require different packaging structures. Our gravure packaging solutions can provide the appropriate printed materials for flexible pouches, continuous rolls, custom labels and all other compatible formats.

Food manufacturers may have a requirement for packaging that will provide protection for freshness and meet the relevant food contact requirements. Pharma brands will have a requirement for appropriate materials and a controlled print process to ensure legibility and compliance. Cosmetics and personal care brands will often have a requirement for attractive colors, high-quality graphics and a premium feel.

The final decision should be based on product sensitivity, storage conditions, shelf life, barrier properties and the package structure itself. Printing in itself won’t give you moisture resistance, product safety or shelf life. Those are all a function of the material and the package design.

Make Large Production Runs More Cost-Effective

Commercial gravure is ideally suited to businesses that are printing in large volumes and who require a very consistent result. Once the cylinders are all in place you can run very high volumes indeed.

Wholesale gravure printing can be a cost effective way to reduce the cost per unit when your order quantities are high enough to justify the set up. It’s a very useful option for manufacturers, distributors and established brands who are reordering the same designs on a regular basis.

However short runs, frequent artwork changes and small product launches may be better served by digital or flexo. The right solution is going to be one that you’ve worked out by comparing setup costs, quantities, turnaround times and finishing.

Support Your Brand with Responsible Material Choices

Businesses are progressively looking at recyclable packaging printing and environmentally-friendly packaging materials. The choice of material should be made with the full package in mind, right through to the inks, adhesives, coatings and laminates.

The use of recyclable substrates and compatible ink systems can go a long way to support sustainability objectives. Always check recyclability against the actual facilities and requirements in your market of interest rather than simply making a general environmental claim.

Get Professional Gravure Printing Services for Your Next Order

Give your packaging the right level of consistency, detail and visual impact. Just send us your artwork, your preferred material, your packaging size and your estimated order quantity and we can go through the suitability of gravure. The color requirements and the production specs prior to quoting.

Contact PackagingXpert today to discuss custom gravure printing with your logo and explore cost-effective options for large-volume packaging orders.