Gravure Printing vs Digital Printing: Which One is Better

Gravure Printing vs Digital Printing: Which One is Better

In the world of flexible packaging, is rotogravure printing (also commonly known as gravure printing) or digital printing better for your product? 

RubeeFlex Packaging, leader in custom packaging, explores both digital and rotogravure techniques, delving into the advantages and disadvantages of each printing method so you can decide which one is right for you.

This article compares gravure printing vs digital printing in terms of technique, cost, and quality..

What is Digital Printing?

Digital printing is a modern printing technology that prints digital files directly onto packaging materials. Digital printing for flexible packaging eliminates the need for printing plates and uses inkjet or laser technology to apply the design directly onto the substrate. 

When fewer bags or packages are needed, digital printing takes an edge over gravure printing because it allows for variable data  printing. For example, a food manufacturer requires different packaging and design for 50 products, but minimal bags of each are needed. Digital printing is most practical in such a case because it is easy and economical to customize unique graphics for each package design without the need for creating separate printing plates. Variable data is a big advantage of digital printing vs rotogravure as each package needs a unique code, address, and name. Rotogravure printing does not have variable data capability.

While there is no doubt that gravure printing is more economical per bag, many businesses do not need large runs of 10,000 or more per SKU, so for them, the best solution is digital printing.

What is Rotogravure Printing?

Rotogravure printing gained popularity in the early twentieth century when the newspaper industry began to use it on a large scale. During the rotogravure printing process, an image is directly engraved onto the paper, box, or packaging. Rotogravure is a form of intaglio printing that uses an engraved metal cylinder as a printing plate. A gravure print involves transferring a design by rolling a cylinder through ink and then onto the printing surface. In packaging, rotogravure printing is used most often to print on thin, flexible material like stand-up pouches, black bottom bags, and more.

The rotogravure printing process produces high-quality prints, especially for large-scale commercial printing, such as gravure packaging or publications.

What are the Advantages of Digital Printing?

  •  Cost-effective: No printing plates or expensive setup, making it economical for smaller runs and customized orders.
  • Flexibility: Print only the amount you need, when you need it with a fast turnaround.
  • Low MOQ (minimum order quantity): Perfect for businesses requiring small to medium-sized printing runs.
  • Variable data capability: Unlimited customization means that names, addresses, codes, and numbering can be changed easily.
  • Improved technology: Digital prints are high-resolution images featuring sharp details and quality colors.
  • Eco-friendly: Less waste materials, such as leftover ink and printing plates.Large quantities can be printed cost effectively

Disadvantages of Digital Printing

  • High cost for large runs: Digital presses and materials cost more than traditional printing methods, causing a higher per-unit cost for large printing runs.
  • Limited substrate options: Digital printing cannot handle every type of substrate, restricting the range of suitable packaging options.
  • Color consistency: Maintaining color accuracy across multiple print runs is more challenging with digital printing. Digital printers may also struggle with exact color matching.
  • Durability issues: Digital prints are less resistant to chemicals, abrasion, and UV light, possibly affecting the appearance or durability of the packaging.

What are the Advantages of Gravure Printing?

  • Economical: Large quantities can be printed cost-effectively due to their low unit price. The more you print, the cheaper the price per piece becomes.
  • Consistency: Consistent presentation for large runs, which is essential for products that need to maintain a uniform appearance.
  • Versatile: Rotogravure packaging is suitable for a variety of materials, such as paper, film laminations, and metallic foils. 
  • Special effects: Custom varnishes and inks, such as metallic and Pantone colors, can be incorporated into the design.
  • High-quality: Rotogravure produces high-quality images and eye-catching designs, including intricate graphics.
  • Efficient: The cylinder printing plate can be reused for multiple print runs.

Disadvantages of Gravure Printing

  • High Initial Investment: The initial cost of producing cylinders or plates  for rotogravure flexible packaging can be very high.
  • Time-consuming setup: Creating and preparing gravure cylinders takes a long time, making rotogravure impractical for projects requiring a quick turnaround.
  • Maintenance: Gravure cylinders, ink fountains, and other parts require regular maintenance and quality control.
  • Eco-unfriendly: Rotogravure printing involves the use of chemicals, which can have negative environmental impacts. As well, the rotogravure printing process often produces a lot of waste.

Gravure Printing vs Digital Printing: Which One Should You Choose? 

Rotogravure and digital are both useful printing methods. Each technique has particular benefits, depending on your project’s requirements. When you need larger runs of a project, rotogravure printing is the way to go.

If a smaller run is needed because you have too many SKUs and can’t print 10,000 of each, or because you want to add a new item to your product line but want to try it first with smaller runs, digital printing is your solution. The best part is that as a business, your needs can be met with either of these choices. The high level of quality of both printing methods ensures you a printed product that will make you look great!

Are you looking for stunning, eco-friendly, and innovative packaging solutions for your products? Do you want your products to stand out on the shelf more than your competitors? RubeeFlex Packaging is the leader in flexible and custom packaging solutions. We’ve produced millions of packages for our clients across multiple industries, including food & drink products, personal care, pharma, and more. Contact RubeeFlex today to launch your product with packaging tailored to your brand and vision.