What Sets Flexo Printing Machines Apart from Gravure Printing Machines?

In the printing and packaging sector, flexo printing machines and gravure printing machines play vital roles—but they aren't interchangeable. Let's clearly outline their key distinctions, especially if you're figuring out which one aligns with your requirements.
 

Printing Principle: Ink Transfer Mechanics

Flexo Printing Machine

Flexo printing leverages flexible relief plates featuring raised image sections. Here's the process: the machine deposits ink onto these raised areas, then transfers that ink straight onto the substrate—be it paper, film, or another material. Picture it like using a rubber stamp: ink clings to the raised portion and gets pressed onto the surface.
 

Gravure Printing Machine

Gravure printing employs cylinders with recessed cells meant to hold ink. As the cylinder turns, ink fills these recessed spots. A doctor blade then wipes away surplus ink, and the ink left in the cells is transferred onto the substrate under pressure.
 

Ink Varieties and Environmental Footprint

Flexo Printing Inks

Flexo printing frequently uses water-based or UV-curable inks. These inks are much more eco-friendly because they give off far fewer volatile organic compounds (VOCs). They're also a secure choice for uses like food packaging, where contact with edible items matters.
 

Gravure Printing Inks

Gravure printing typically relies on solvent-based inks. These inks release more VOCs during printing, which can damage both the environment and workers. What's more, materials printed with these inks are harder to recycle.
 

Optimal Uses: When Each Machine Shines

Flexo Printing

Flexo printing excels in short to medium print runs. It's ideal for packaging products like labels, cardboard boxes, and flexible bags (such as those for snacks). Another plus? Its flexible plates let it adapt better to uneven surfaces.
 

Gravure Printing

Gravure printing is best for large print runs—think millions of copies. It's widely used for high-volume items like magazines, wallpaper, and long-run packaging. It creates extremely crisp images and consistent colors, which is perfect for detailed artwork.
 

Cost Factors

Flexo Printing

Setting up a flexo printing machine is more budget-friendly. The plates are cheaper to make, and switching between print jobs is faster. This makes flexo a cost-effective pick for smaller batches or jobs that need frequent design tweaks.
 

Gravure Printing

Gravure printing has higher initial costs. The cylinders are pricey to produce, so it only becomes cost-efficient for extremely large print quantities. Changing designs is also expensive and time-consuming, so it's not good for jobs that need regular updates.
 

Conclusion

To put it simply, flexo printing uses raised plates and more eco-friendly inks, making it great for shorter runs and various materials. Gravure printing uses recessed cylinders and solvent-based inks, excelling at large runs with sharp detail.

If you need a printing solution that's flexible, eco-conscious, and works for different packaging needs, a Flexo Printing Machine is likely the right choice. To check out our selection of flexo printing machines, head to our product page.