Gravure Printing Explained: High-Quality Printing for Mass Production

การพิมพ์แบบ Gravure คืออะไร?

Gravure printing is one of the oldest methods of printing that is widely used in the field of high-volume, high-quality printing. From the colorful food packaging that adorns supermarkets to the glossy prints of the magazines that you read, the imprints of gravure cannot be missed. This printing technique is popular for its ability to produce both high-quality and cost-efficient prints in large quantities. It is time to explore the details of this rather interesting technology of printing.

In its essence, gravure printing is a type of intaglio printing, a printing method that involves engraving the image to be printed directly on the surface of a cylinder. Unlike relief or planographic printing, gravure employs small engraved or etched cells on the surface of the printing cylinder to hold ink. This method is famous for its capability to provide great control over the amount of ink deposited on the paper, which gives it deep and saturated colors and smooth transitions between them, which is why it is one of the most important processes in commercial printing.

The Intricate Process of Gravure Printing Explained

Cylinder Preparation: The preparation of the printing cylinder is the key to rotogravure printing. The desired detailed images are either mechanically engraved using diamond styluses, chemically etched with acid or ablated by laser on a copper cylinder. This process forms small depressions that will be used to contain the ink later on.

Inking: After the preparation of the cylinder, it goes through an ink fountain to ensure that the recessed cells are filled with gravure printing inks. The type of ink used is very important and depends on the nature of the substrate to be printed and the intended use of the printed material.

Doctor Blading: The next process is to wash off any excess ink on the surface of the cylinder which is not to be printed on. This is done by means of a doctor blade, which is a thin and flexible steel blade that is placed in contact with the rotating cylinder. The doctor blade works as a scraper that removes excess ink while ensuring that ink remains only in the engraved cells.

Printing: The substrate which can be a paper, plastic film thickness or aluminum foil is then fed between the inked gravure cylinder and a pressure roller known as the impression roller. The impression roller applies controlled and even pressure on the substrate to ensure that it comes into contact with the ink-filled cells on the surface of the cylinder. This pressure helps to transfer the ink from the recessed cells onto the substrate and thus replicating the engraved image.

Drying: The last process of the gravure printing method is the drying of the freshly printed substrate. After passing through the printing nip, the material goes through a drying unit. The type of drying system to be used depends on the type of ink used in the printing process. Some of the common methods include circulation of hot air to evaporate solvents or water in the ink, infrared drying that uses heat radiation to dry the ink and ultraviolet or UV drying that uses UV light to cure UV sensitive inks.

Key Advantages That Make Gravure Printing Popular

Gravure printing has remained popular due to its high quality of print that is characterized by high color density, smooth gradations and fine details. It is suitable for large production volumes, which makes it economical for large scale production runs. The process has high efficiency of ink transfer and the cylinders used are very strong to withstand the rigorous use. In addition, gravure can print on films, foils, and paper, which makes it suitable for various packaging and publishing industries that require high quality and large production.

Understanding the Limitations and Disadvantages

However, gravure printing has its drawbacks. This is because cylinder preparation is expensive at the beginning and therefore not ideal for short runs. The use of traditional solvent based inks is a problem because of the VOC emissions, but water based and UV inks are being developed. Cylinder preparation can also be a lengthy process and may need the services of a professional. Last but not the least, design modification after cylinder engraving is costly and time consuming as it requires new or modified cylinders, which increases the cost and time taken to make design alterations.

Gravure Printing vs. Other Printing Technologies

คุณสมบัติ	การพิมพ์แบบกราเวียร์	การพิมพ์แบบเฟล็กโซกราฟฟิก	การพิมพ์ออฟเซต
คุณภาพการพิมพ์	Excellent (smooth tones, fine detail)	Good (improving with advancements)	Very Good (sharp images, good color)
Cost (Initial)	High (cylinder preparation)	Medium (printing plate preparation)	Medium (printing plate preparation)
Cost (Per Unit)	Low for long runs	Low to Medium for medium to long runs	Medium for medium runs
ความเร็ว	สูงมาก	สูง	ปานกลาง
Substrates	Wide range (films, foils, paper, textiles)	Wide range (flexible packaging, paperboard)	Primarily paper and some thin films
ประเภทหมึก	Solvent-based, Water-based, UV-curable	Water-based, Solvent-based, UV-curable	Oil-based, UV-curable
Run Lengths	เหมาะสำหรับการวิ่งระยะไกลมาก	Suitable for medium to long runs	Economical for medium runs

Diverse Applications of Gravure Printing Across Industries

The exceptional quality and versatility of gravure printing have led to its widespread adoption across a multitude of sectors. Here are some of the key industries that heavily rely on gravure printing for their production needs:

• Packaging Industry (Food packaging, Beverage, Tobacco, Pharmaceuticals, etc.)
• Publishing Industry (printing of magazines, Catalogs, Direct Mail)
• Wall coverings and Floor Coverings
• Textile Industry
• Security Printing (Banknotes, Stamps)
• Flexible Electronics
• Solar Panels

From consumer goods to specialized technical applications, gravure printing plays a vital role in delivering high-quality printed products across a diverse range of industries.

Is Gravure Printing Machine Worth the Investment? Cost-Effectiveness Analysis

Gravure printing machine is a capital intensive investment that should be made based on the production capacity and quality requirements. The cost of cylinders and the press is relatively high, especially when compared to other methods, but the long-term cost per print run is often very competitive. Large and constant print runs are ideal for this type of press because of the high speed and long-wearing cylinders, which translate to lower cost per thousand. The improved print quality also increases the aesthetic value of the product and the brand image, which is a good reason to invest in the technology. Ink efficiency and cylinder durability also add to the cost savings, which makes a gravure printing machine a possibly tactical and financially viable solution for companies with high and constant usage and high-quality requirements.

Key Considerations for Choosing the Right Gravure Printing Machine

When choosing the gravure printing presses, there are several important factors that need to be considered to ensure that the right equipment is chosen for the production process of the company.

Production ปริมาณ Requirements: Assess your anticipated print volumes. Gravure presses are available in different types depending on the speed and the number of prints per minute. Select a machine that will meet your current and future production needs in the best way possible.

พื้นผิวความเข้ากันได้: Determine the type of packaging material that you will be printing on. Make sure the selected machine can handle the necessary substrate types and thicknesses, whether flexible films and foils, paper, or other materials.

Print Quality Expectations: Decide on the level of print quality that is needed for your applications. Some of the aspects that should be taken into consideration include the resolution, color reproduction, tonal range, and the ability to produce detailed images. The quality of gravure press and the cylinder engraving may also vary depending on the configuration of the gravure press.

Number of Colors: Determine the number of colors you usually require in your prints. Gravure presses can be single color or multiple color, from two to twelve or more. Choose a machine that has the right number of printing stations.

Web Width: Take into consideration the maximum width of the material that you will be printing. The web width of the machine should be chosen to be wide enough to handle your largest print jobs comfortably.

Automation and Control Systems: Assess the extent of automation and control systems available in the machine. Some of the features that can affect print quality, productivity, and wastage include automatic color registration, tension control, and defect detection systems.

Ink and Drying Systems: Understand the type of gravure printing inks that you intend to use whether solvent based, water based or UV curable and ensure that the machine has the right ink and drying systems. Some of the factors that should be taken into consideration include the drying speed and the energy consumption.

Budget and Total Cost of Ownership: Set a budget for the machine and also look at the total cost of the machine, the cost of ink, energy, maintenance, and the cost of preparing the cylinder.

Supplier Reputation and Support: It is important to establish the credibility of the gravure printing machine supplier. They should consider their experience, technological know-how, after-sales support, and spare parts and technical support.

Selecting the Right Gravure Printing Machine: Why KETE is the Ideal Partner

Selecting KETE as your rotogravure printing press supplier means getting access to the innovative and effective solutions in the field of rotogravure printing. Our machines, including the ELS and MLS series, are suitable for various materials such as PVC, aluminum foil, BOPP, and paper, which are widely used in packaging materials. KETE has options up to 400m/min with functions such as automatic color register for high-volume production. KETE has been exporting to over 80 countries and selling over 2000 machines per year, offering ISO9001 and CE certified machines, supported by experienced engineers and professional after-sales service, which makes KETE a strategic and reliable partner for your business development.

Contact us:

• Address: 20th Floor, Xinchao Building, Anyang Street, Ruian City, Wenzhou City, Zhejiang Province, China 325200
• Phone: +86-577-66873227 / 66689036 / 66689037
• WhatsApp / WeChat: +86-18806770163
• E-mail: ติดต่อฝ่ายขาย@ketegroup.com

บทสรุป

Gravure printing is still a very useful technology for any company that needs to print large volumes of high quality images. It is used in packaging, publishing and many other industries due to its ability to produce rich colors, fine detail and consistency at high speeds. Although the initial cost is comparatively higher than some of the other methods of printing, the cost effectiveness and the quality of the prints that gravure offers for large scale and long term production makes it a more suitable option. By gaining knowledge about the rotogravure process and the factors that may affect it, you will be able to choose the right gravure printing solution that will help you achieve your business goals and provide you with the best quality prints.