Rotogravure vs. Flexographic Printing: Which One Is Right for Flexible Packaging?

Choosing between rotogravure and flexographic printing in flexible packaging depends on several factors, including print quality, production volume, budget, and substrate type. Here’s a breakdown of the main differences and when to choose each.

---

1. Rotogravure Printing

🛠️ How It Works

Ink is held in engraved cells on a metal cylinder and transferred to the substrate under pressure.

✅ Rotogravure Advantages

• Superior print quality: High-resolution printing with fine detail, smooth gradients, and exceptional sharpness.
• Color consistency: Excellent repeatability across long runs with minimal color variation.
• Substrate versatility: Ideal for plastic films such as BOPP, PET, PE, and others.
• Durability: Engraved cylinders are long-lasting and suitable for high-volume production.

❌ Disadvantages

• High initial cost: Cylinder engraving is expensive, making it less practical for short runs.
• Longer setup times: Requires more time to adjust and switch designs.

---

2. Flexographic Printing

🛠️ How It Works

Uses flexible photopolymer plates mounted on rollers. Ink is transferred directly onto the substrate through contact.

✅ Flexo Advantages

• Lower initial cost: Plates are cheaper to produce than rotogravure cylinders.
• Faster changeovers: Easier design changes and quicker setup.
• Efficient for short to medium runs: Ideal for brands with frequent design rotations.
• Lower ink usage: Typically consumes less ink, reducing operating costs.
• Sustainability: Compatible with water-based inks, which are less polluting than solvent-based inks used in rotogravure.

❌ Disadvantages

• Lower image quality: Less precise with fine details and gradients compared to rotogravure.
• Color consistency issues: Solid color areas may show variations between runs.
• Shorter plate lifespan: Flexo plates wear faster than rotogravure cylinders.

---

🧩 Which One Should You Choose for Flexible Packaging?

Need	Best Option
Premium print quality and long runs	✅ Rotogravure
Lower cost, flexibility, and quick design changes	✅ Flexography
Complex graphics for high-end packaging	✅ Rotogravure
Medium runs with recurring SKUs	✅ Flexography

---

🧠 Final Thoughts

While both technologies have evolved, flexo printing has greatly improved with high-definition plates and anilox rollers. Still, rotogravure remains the gold standard for premium, high-volume flexible packaging.

---

💬 Need help choosing the best printing method for your packaging?

Contact Blue Pack Solutions – Smarter Packaging, Sustainable Solutions.