Flexo vs Rotogravure Printing Machines: What’s the Difference?

Quick Overview

Both flexo and rotogravure are high-speed, roll-to-roll (web) printing processes widely used in flexible packaging, labels, and specialty applications. Flexo uses flexible relief plates and anilox rollers to transfer ink, while rotogravure uses engraved cylinders to carry ink in recessed cells.

How Each Process Works

Flexographic Printing (Flexo)

• Relief method: A flexible photopolymer plate carries the raised image.
• Anilox roller meters a precise ink film to the plate.
• Excels with water-based, solvent, UV, and EB-curable inks on many substrates.
• Common in labels, pouches, corrugated, folding cartons, and shrink sleeves.

Rotogravure Printing (Gravure)

• Intaglio method: Image is recessed into an engraved metal cylinder.
• Doctor blade wipes the surface, leaving ink in the cells; impression transfers ink to the substrate.
• Renowned for ultra-consistent solids, smooth vignettes, and very long runs.
• Common in high-volume flexible packaging, decorative laminates, and specialty publication work.

Flexo vs Rotogravure: Comparison Chart

Costs and ROI

If you run many SKUs with frequent design changes and moderate volumes, flexo typically delivers the best ROI due to low plate costs and rapid changeovers. If you print a few SKUs in extremely high volumes (tens of millions of impressions), rotogravure’s higher cylinder cost is offset by unmatched consistency, speed, and uptime.

Print Quality and Color Management

• Flexo quality has advanced with HD plates, finer anilox line screens, and precise tension control, achieving near-gravure quality for many packages.
• Gravure’s engraved cells produce exceptionally even ink laydown, deep solids, and stable color across marathon runs.
• Both benefit from spectrophotometric control, ECG (extended color gamut) workflows, and ISO-compliant print targets.

Speed and Efficiency

Both press types can run at very high web speeds. In practice, scheduling and changeover determine throughput. Flexo’s faster plate swaps make it ideal for shorter runs and versioned work. Gravure presses shine on long, uninterrupted campaigns where stability and consistency matter most.

Sustainability Considerations

• Flexo: Easier to implement water-based inks and fast washups; reduced VOCs and energy use.
• Gravure: Often uses solvent-based systems and longer dryers; solvent recovery and energy optimization are essential to lower footprint.

When to Choose Flexo vs Rotogravure

Choose Flexo if you need:

• Short-to-medium runs or frequent design changes.
• Lower setup cost and faster time-to-press.
• Broad substrate compatibility, including corrugated and paper.
• Water-based or UV ink options for sustainability or compliance.

Choose Rotogravure if you need:

• Ultra-long runs with tight color stability and minimal drift.
• Premium solids, smooth gradients, and photographic fidelity.
• High-speed film printing with consistent laydown for lamination.
• Cost efficiency at massive volumes that justify cylinder engraving.

Real-World Examples

• Flexo: Private-label snack line with 30 SKUs, frequent seasonal changes, water-based inks on paper and film.
• Gravure: Global confectionery brand running a few flagship SKUs continuously at very high volumes on BOPP film.

Recommended Images to Include

Replace the placeholders above with:

• Close-up of a flexo anilox roller and photopolymer plate (alt: “Flexographic anilox roller and photopolymer plate”).
• Close-up of a gravure cylinder cell structure (alt: “Rotogravure cylinder microcells under magnification”).
• Side-by-side sample prints showing solids and vignettes (alt: “Flexo vs rotogravure print quality comparison”).

FAQs

Is flexo cheaper than rotogravure?

For short and medium runs, yes—flexo plates cost less and changeovers are quicker. For very long runs, gravure can achieve lower unit costs.

Which has better print quality?

Gravure generally delivers smoother vignettes and deep, even solids. Modern flexo can match or approach gravure quality for many applications with the right plates and controls.

Which is more sustainable?

Flexo often has an edge due to water-based inks and lower energy for drying; gravure sustainability depends heavily on solvent recovery and energy management.