Gravure Printing vs Flexo: An In-Depth Comparison for Industry Experts

Gravure printing and flexographic printing are two of the most popular printing methods in the commercial and industry printing industry, each offering distinct versatility. Whether it’s magazine covers or flexible packaging, both play a key role in producing high-quality printed materials. However, their differences in terms of cost efficiency, lead time, image quality, substrate compatibility, and sustainability have long been the subject of debate within the industry.

This article explores the features of both gravure and flexo printing, breaking down their similarities and differences to help you make well-informed choices for your projects.

What is Gravure Printing?

Gravure printing, also known as rotogravure printing, is an intaglio printing process where images are engraved onto the surface of a metal plate (usually steel or copper) or cylinder. Gravure creates small, recessed cells on the plate which vary in depth and size, depending on the image detail you need. These cells are where the ink sits. As the impression cylinder rotates, excess ink is scraped off by a doctor blade, and only the ink within the cells is transferred to the substrate, creating the final image.

What is Flexo Printing?

Flexographic printing (or simply flexo printing) is a relief process, fundamentally different from gravure. In flexo, the image carrier consists of a flexible relief plate made from polymer or rubber, where the raised image areas are coated with ink and transferred directly to substrates. Flexographic printing process makes use of rollers such as the anilox roller, which carries a precise pattern of cells filled with ink, helping to evenly disperse it across the raised surface of the plate.

Gravure vs Flexo: What They Have in Common

It is understandable why people fail to differentiate between gravure and flexo printing since they are widely used in large-scale printing and offer exceptional results. But they do share some important similarities.

• Both processes use printing plates to transfer images onto substrates.
• Both are designed for high-speed, roll-to-roll (web) printing operations.
• Both are well-suited for large-volume production runs.
• Both can deliver high quality results with fine details and excellent color reproduction.
• Both support a wide variety of substrates, from paper to films and foils.

Flexo Printing vs Gravure Printing: What Sets Them Apart

Costs

Gravure printing entails significantly higher upfront costs compared to flexo, largely due to the gravure image carriers. The plate, often made use of a metal plate, requires precision engraving, which not only takes time but also significantly adds to the initial expense. For smaller, short-run projects or projects that frequently change designs, it is a less attractive option as each new plate comes with a hefty price tag. However, once the metal plates are made, they can endure millions of impressions, making them a cost-effective solution for larger print jobs.

Flexo printing, by comparison, uses rubber or photopolymer plates, which are cheaper and faster to produce—especially with technological advances in photopolymer plate making. This makes flexo ideal for mid-size or shorter runs. However, the downside is that flexo plates tend to be less durable, typically lasting between 50,000 to 200,000 impressions, depending on conditions, meaning higher replacement costs over time—especially if the same design is used across multiple print jobs.

Lead Times

Flexo printing stands out for its quick setup and minimal downtime, making it highly efficient for handling multiple short-run jobs. The faster plate production and shorter make-ready times mean flexo presses can switch between orders quickly, allowing for faster delivery on smaller or frequent jobs.

While gravure printing takes longer in the preparation stage — especially with engraving metal plates — it becomes incredibly efficient once in full production. Gravure is ideal for large, long-term runs, where it operates at high speeds with minimal interruptions, making up for the slower start. For high-volume production, gravure can even surpass flexo in overall efficiency due to its ability to print non-stop for extended periods.

Printing Quality and Precision

Gravure printing excels in image precision and higher resolution output. It can lay down thick, consistent ink layers, capturing incredible detail and producing sharp, vibrant images—ideal for printing tasks that demand absolute color accuracy and continuous tone images. This makes gravure the top choice for high-end packaging and fine art reproduction, where even the smallest details must remain sharp over large volumes.

Flexo printing has made significant technological advances in recent years, improving its resolution and color consistency. However, it still cannot match gravure’s level of fine detail, especially over long runs. Flexo may experience slight variations in color intensity during extended print jobs. That said, flexo is now more than capable of handling many jobs once dominated by gravure, offering a compelling balance of quality and cost efficiency for medium-to-high quality needs.

Substrate Compatibility

Substrate compatibility is one of the pivotal points of differentiation between gravure vs flexo printing. Flexo printing offers versatile substrate options that include both porous and non-porous materials, such as paper, film, plastic, or corrugated boards. This makes flexo a superior choice for industries that require packaging for different types of materials, especially in food packaging where the choice of materials can vary broadly.

On the other hand, gravure printing works exceptionally well with non-porous substrates such as plastic, foil, and laminated paper. Gravure produces a smooth and consistent coating of ink on challenging substrates but may not always perform as well on rough, uneven surfaces where flexo excels. For large runs requiring a uniform finish across a smooth substrate, gravure’s more intricate capabilities often make it the superior method.

Range of Ink Options

Flexo printing offers greater versatility in choices of inks. It supports water-based, solvent-based, and UV-curable inks. This adaptability allows printers to experiment with various types of flexographic inks to achieve desired results across diverse substrates. The ability to use UV inks is particularly convenient for packaging materials where quick drying and durability are critical, such as in the production of magazine covers or promotional packaging.

Gravure printing, on the other hand, is far more restricted. It predominantly relies on solvent-based inks. While gravure delivers excellent results with these inks, for printers needing a variety of ink solutions for different applications, flexo printing clearly provides greater adaptability.

Environmental Considerations

Flexo printing is generally considered more environmentally friendly. The use of water-based inks and more environmentally conscious production methods results in reduced emissions and less waste, making it a cleaner option, particularly for companies prioritizing sustainability.

By contrast, gravure printing primarily relies on solvent-based inks, which can be harmful due to their VOC emissions. It also tends to use more ink per print, adding to the sustainability challenge. While efforts are being made to advancements in gravure technology, such as developing more efficient image carriers and experimenting with water-based inks, flexo remains the more eco-conscious choice for now.

Gravure vs Flexo Printing: Which is Better?

It’s challenging to declare a clear winner between flexo and gravure printing, as both have their own unique strengths and weaknesses.

• Gravure excels in high-resolution, consistent print quality, especially for long-run projects.
• Flexo offers quicker setup times and lower costs, making it ideal for short-to-medium runs.
• Gravure plates last for millions of impressions, making long-term production more efficient.
• Flexo plates are cheaper and faster to produce, accommodating frequent design changes.
• Flexo supports a wider range of inks, while gravure delivers unmatched image detail.

If print providers must choose between the two technologies, the decision isn’t only about quality or cost—it’s about regional market trends and customer preferences. Continents have specific preferences, influenced by historical trends, industry needs, and technological infrastructure.

Region	Flexo Preference (%)	Gravure Preference (%)
North America	70	30
Europe	60	40
Asia	40	60
Latin America	55	45

Globally, there is a clear movement towards flexo printing, especially in the packaging sector, due to faster setup and cost efficiency. However, gravure is still the forte when it comes to high end, long run production, more so in Asia and any sort of industry that is detail driven.

Conclusion

In comparing gravure printing vs flexo, each printing technique has its distinct merits and intended purposes within the world of commercial printing. Simply put, gravure’s promise of fine detail and longer runs shines brightest in large-volume and precision-focused applications, while flexographic printing’s flexibility, cost-effectiveness, and versatility in substrate compatibility make it the go-to for more dynamic print environments requiring shorter runs and faster turnarounds.

However, as technologies advance, the lines between the two continue to blur. The adoption of digital technologies and hybrid printing solutions is pushing both gravure and flexo into new territory, potentially changing how professionals make their choices in the coming years. In any case, whichever method you choose, understanding the distinct advantages and compromises of each is key to making an informed decision that suits the specific needs of your print job.

Reach Out to KETE for Advanced Printing Machines

For printing professionals looking to expand their operations or upgrade their technology, finding the right equipment partner is essential. At KETE, we specialize in providing high-quality, cutting-edge printing machinery that caters to both flexo and gravure printing needs. Whether you’re seeking solutions for high-volume gravure printing projects or need flexo printing machines capable of shorter runs and quicker setups, KETE is driven by a commitment to excellence in the printing industry.

Our team of experts is ready to help you match the right machine with your operational goals, ensuring that you’re equipped to meet customer demands, enhance print quality, and reduce costs. We believe in offering personalized service and industry insight so that you can make an informed final decision about your printing investments.

Feel free to reach out to KETE for a consultation and learn more about how we can help take your printing operation to the next level—whether through flexographic process or gravure technologies.