Another key differentiator in flexo vs. gravure is the range of inks flexo is able to print with. In printing, anilox is a method used to provide a measured amount of ink to a flexographic (flexo) printing plate. })(document, 'script', '//demo.citrus.ph/?p=134&ph_apikey=42de92a5dd4ac09fe15ae8f8c85302a6'); Copyright Lead Yuan Flexo 2019 | Powered by: Citrus.ph, Hi! In the case of flexo, there are pre-press costs associated with each run, as the following examples will show. For gravure printing, the image has to be transferred to the substrate with a metal plate. In this process, ink is applied to a relief plate cylinder, which then prints the relief design onto the label material. Rotogravure printing is a newer technology that relies on engraved individual cylinders to produce the printed image. Save my name, email, and website in this browser for the next time I comment. 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 cylinders weigh heavier, hence cannot be piled on top of each other. Let our team guide you through the pros and cons of the most common print technologies used in packaging. Ink dries too fast for anilox volume, does not adequately replenish anilox Solution: 1. Plates. • Direct printing process gave the best print quality. • Sturdy robust machines with excellent web path and drying giving a very stable and consistent print. Flexo – Indirect printing. ph.type = 'text/javascript'; Both commercial printing methods are great at producing high-quality and high-resolution prints. 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. Flexographic printing, or flexo, is a relief printing technique similar to letterpress that employs rubber or soft plastic plates, a simple inking system and fast drying inks. Each type of printing has a niche or application where it is best suited. Two technologies that are often compared are letterpress and flexo printing. This is the image carrier and contains all the text or images which eventually get printed on the substrate. To produce an impression, letterpress printers had to construct individual letters and characters into a "forme", secure them into a … Screen printing. On the other hand, a rotogravure cylinder costs US$0.02 – US$0.03, and a cylinder can last over 100M rotations. Flexographic job changing only takes 0.75 to 1.5 hours and substrate wastage is only at 80-100 meters. Flexography Printing Press Flexography, also known as “flexo,” is a printing process which employs the use of pliable relief or raised image plates. 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). Very high speed capability makes flexo printing more efficient for the big jobs. The cliché contains raised printing surfaces which prints the ink on the substrate. Printers and label makers use four main types of printing processes packaging: flexographic, digital, gravure, and offset. Disadvantages. The team typically replies in a few minutes. Flexo, Litho and Letterpress, because of their different ink delivery systems employed, cannot usually do this without severe compromise in quality. Flexo – Indirect printing. The only difference is the versatility of use and cost of production. 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. Unlike litho printing, flexo plates can be reused. Digital Printing vs. Flexographic Printing. Both commercial printing methods are great at producing high-quality and high-resolution prints. However, you should also think of the cost of repairs or replacements in case of damage. The latter only has a 120-200 meters per minute running capacity. In comments to FLEXO Magazine , David Walsh of market research and technical PR firm LPC, says, “Flexo or conventional presses are not going away. These plates are flexible photopolymers that are positioned around web press cylinders that rotate. 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 high efficiencies associated with low cost gravure inks and high running speeds. • Slow ink down • Add extender • Use coarser anilox • Reduce press speed Ghosting Problem: Part of image not printing; resembles an offset of same image. This process is used in high-volume web fed printing products such as magazines, newspapers, brochures, packaging and in … 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. 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. 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. It’s got a sunken surface where ink is applied and then wiped off before it’s applied. We can use either method to tailor-make a printing solution to suit your individual needs. In this blog, I’ll explain the way those two technologies work, and list some advantages and disadvantages of both. "In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo. High-quality flexographic printing has never been as easy as it is today. Can print up to 6 colors. It’s more versatile and … The plate is inked, with the inked image being moved to the printing surface afterwards. In most cases, flexo printing ink is the superior choice due to the ease of printing with a wider variety of inks. Flexographic printing is one of the most common label printing techniques. Etiam sit amet orci eget eros faucibus tincidunt. The process was first used in publication and the nature of that business was usually a one-shot run. There are many misconceptions about the relative costs of rotogravure vs. flexography. Aside from the pre-press costs, printers should also consider some of the other advantages of rotogravure: Dick Chesnut But flexographic printing is more efficient for longer production runs, having fast lead times, fewer ink costs, and reduced energy consumption. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. Can’t decide on the printing method to use for your business? 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. Click one of our member below to chat on. Gravure Printed Tape. ph.charset = 'UTF-8'; Louis Adhesive Tapes is now able to produce Printed tape using two distinctly different methods: Gravure printing and Flexo printing. 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 … Generally speaking, most printers of Flexible Packaging aren't familiar with Offset printing. It’s more versatile and diverse than gravure printing. When changing jobs, a printing press can also waste substrates in the process. There are significant disadvantages to purchasing a used flexo press. 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 . 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. . The printing cylinder is inked and the ink is moved onto the paper medium. 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. If you’re looking to make the switch from gravure printing to flexography, here’s how to make a smooth transition. Right after the Gutenberg Press popularized movable type back in the 15th century, letterpress had been the predominant printing technique for five centuries. 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. Conventional flexo printing has five, six, seven, eight, etc. Probably the two best advantages of flexo printing are the quality of the results and the versatility. With our integrated web-fed printing solutions, we create a … President 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. It’s evident that the cylinders for rotogravure printing are much cheaper. This printing technique allows a lot of flexibility with label material. Worth noting is that you should be leaning to brand new machines instead of used ones. Each type of printing has a niche or application where it is best suited. This setup is for a typical long run (more than 12,000 labels) application. Advice on Finding Your Next Job in the Printing Industry. 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. 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. The type of aqueous coating required depends heavily on the application. Gravure and flexo, two primary printing processes, continue to compete head to head in the packaging market segment. Both printing technologies boast of the ability to, print high-resolution images on different substrates. The classic letterpress technology. Lithography production costs more, and presses can be very expensive. Here, again, the costs vary substantially depending on where these are being procured. Lithography is used for anything that needs vibrant colours and is … The ability to create reverse printed laminated labels in-line. 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. Gravure printing is a process where the desired image is engraved into a cylinder designed for printing. Gravure printing vs. Flexo printing Printing Cylinders and Plates. By some estimates, the industry may see a decrease as high as 18 percent between 2014 and 2024. Gravure is gradually losing market share to offset for publication printing and to flexo for packaging applications. Both printing technologies boast of the ability to print high-resolution images on different substrates. Flexographic vs. Rotogravure Printing: What’s Right For You and Your Budget? Excellent color quality and consistency using “hd flexo plates” across long runs. Fax: (973) 227-7873 What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. Printing-press cost works out to be considerably higher in rotogravure printing as compared to flexographic printing. 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. This has been possible thanks to the recent advancements in Press design, Printing Plate and ink technology. So should one get damaged, you can save on costs by only purchasing a replacement for the damaged region. But what does that mean for flexographers? Digital printing is a complementary process to flexographic printing — the two can happily co-exist side-by-side. Posted at 01:43h in Flexography, Printing by admin 0 Comments. Worth noting is that you should be leaning to brand new machines instead of used ones. Flexography, on the other hand, uses a rubber plate with a raised surface. with a lot of local manufacturers of printing presses. 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. Compared with gravure open ink tank, flexo solvent consumption is 40% to 50% lower than gravure printing.. Flexo printing vs offset printing: the pros and cons. 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 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. For custom printing, flexographic vs lithographic is an age-old debate, as these two are conventional methods in the printing and packaging industry. var ph = d.createElement(t), s = d.getElementsByTagName(t)[0]; 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. 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. In spite of these facts, employment prospects for printing specialists are still favorable. 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. It guarantees high-quality images. . Flexographic vs. Digital Printing. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. Ease of handling lightweight films at high speeds with tight register control. The cost of a roto engraving is essentially based on size and area, more so than difficulty. In flexography printing (abbreviated to flexo) the plate cylinder is covered with a cliché. A flexographic printing press runs faster than a rotogravure press. But a flexographic plate is built by region. Today, there are two main types of printing: rotogravure and flexographic. 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. Though these two have the ability to print high-quality images on a vast array of substrates, they differ in terms of production cost. In rotogravure printing, the job changing process takes 1.5 to 2 hours long, wasting 200-300 meters of the substrate. The only difference is the versatility of use and cost of production. Rotogravure printing uses metal plates to transfer images onto the desired substrate. The differences between the two methods are outlined below. The cost of storage investment would be higher for the rotogravure process than the flexographic process. The average storage area you need for flexographic plates, anilox, and sleeves is 200 square meters. The flexographic printing process offers more versatility and efficiency, so if you compute the numbers, it definitely does cost less than rotogravure printing. Flexography, on the other hand, uses a rubber plate with a raised surface. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. Letterpress is the "godfather" of printing. colors, possibly including white and other spot colors. s.parentNode.insertBefore(ph, s); This is a very significant point, when comparing pre-press costs. It’s true that digital printing does offer certain strengths in comparison to flexographic printing. 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 Colors can be produced with shading. There are, significant disadvantages to purchasing a used flexo press. Flexo Printing – Pros and Cons. Flexo printing is excellent for runs between 50,000-1mm pieces or large size requirements. Flexo printing. According to CI-Flexo-Tech, the average flexographic plate cost about USD0.03 ~ USD0.045 per square centimeter. When it comes to choosing the right printing method for businesses, two familiar types are always put to battle: flexographic printing and rotogravure printing. Advantage gravure. We can use either method to tailor-make a printing solution to suit your individual needs. Flexographic Printing. Fairfield, NJ 07004, USA Trying to find the perfect format, features, materials and finishes can be a headache. 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. 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. Digital Printing vs. Flexographic vs. Gravure Printing Flexographic Printing . Same as Example A except (9) colors flexo, 4/c process, 3/c line, plus white and metallic. The production process also costs much less. 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. This is compared to the 160 ton/10K.m^2 electric consumption of rotogravure printing. Here are some helpful ways to distinguish which printing process will be used for your next order. Gravure Sheetfed Offset UV Web Offset News Ink HOME Flexography Troubleshooting Guide Cause: 1. These two are the most popular commercial printing methods — not to mention the most reliable. Rotogravure printing, also known as gravure, is a printing process that uses rotary printing. See the full range of CDI Spark and CDI Crystal imagers Version changes are time-consuming to make; It is for good reason that flexographic printing is … However, one outweighs the other when it comes to costs. 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 presses have individual print stations arrayed linearly. On the other hand, a rotogravure press of the same class costs about US$2.3M. Bulk printing is a tedious task and does require some level of optimization. The gold and the Supreme Award jobs at Flexo Tech Print Awards 2017 were also made with Marvaco expanded gamut (EG) printing. It’s got a sunken surface where ink is applied and then wiped off before it’s applied. 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Utilises flexible plates for a typical long run ( more than 12,000 labels ) application tedious and! One of the job changing only takes 0.75 to 1.5 hours and substrate wastage is only 80-100. So, you ’ re made of lightweight and flexible materials like and... Of aqueous coating required depends heavily on the substrate my name, email, and sleeves is 200 meters... Most cost-effective packaging, without compromising pack quality and drying giving a very precisely engineered product that is to...