Still Going Strong

Gravure’s unmatched quality holds up a large part of the flexible packaging segment.

June 2008 by Chris Mc Loone

multipage

As an example, package printer Gilbreth Packaging’s business has increased by approximately 30 percent, according to Alan Wolk, vice president of operations. “We have not been affected by the current economic down swing. Our raw material [prices] are going up, and that is being driven by the increases in demand of oil.”

Micha Noah, R&D Manager, Tadbik Pack (Teradion, Israel) adds, “Tadbik Pack has grown sales 30 percent over the past year compared to the same period in 2006-2007.”

Applications abound

Noah says Tadbik has found great success in printing on very thin substrates, which allows the company to create beautiful shrink sleeves and in-mold labels, both of which give a no-label look. “The gravure stations on our combination presses are a large part of that—the rich white, metallic and pearlescent inks, and the ability to create gloss and matte effects with varnishes—add great elegance to our shrink sleeves and in-mold labels.” He adds that Tadbik also uses gravure for inks with special-effect pigments and for strategic application of glue to hold shrink sleeves in place.

According to Magen, retortable packaging is one of CLP Industries’ largest markets for gravure, “though we also use gravure for coffee laminates and packaging for hot-filled beverages, chocolate-coated sweets, soups, detergents, wet wipes, engine oil, antifreeze, and laundry liquids. We are also exploring other uses for gravure technology, including flexible printed circuits.”

Printed electronics is an emerging area for gravure use. Kirchhoff states, “There has been a surge of information recently about gravure-printed electronics.” Magen says CLP is excited about printed electronics. “That’s a technology that has the promise to be huge from the perspective of both lamination and gravure, as well as for electronics in general.”

Trying to narrow down the prevailing gravure application is more difficult than one might think. Kirchhoff cites the need for high-quality graphics and fine print on flexible packaging. Wolk says that because of the quality expectations for labels and flexible packaging, these two sectors are the most prevalent for gravure printing.

Tadbik Pack uses gravure primarily for shrink sleeves and in-mold labels for injection and blow-molding, whereas Magen states CLP’s gravure presses are dedicated to laminates for pouches and roll stock. That being said, Magen asserts that, “Whenever a combination of superb appearance and high functional qualities is required, as with retort pouches, we prefer applying the gravure technology.”

Challenges remain

Gravure is enjoying widespread usage in flexible packaging and labeling applications, but gravure printers must keep an eye on flexo, which continues to nip at the heels of gravure in terms of price and quality. What gravure printers are saying, however, is that gravure and flexo have their places in flexible packaging and labeling. “I think gravure is still holding its own in the shrink sleeve market,” says Wolk. “Most of our customers still want the quality in their labels that the gravure process yields. Flexo has made some inroads through plate and ink technologies but still doesn’t rival the gravure printing process.”

Wolk says, “Flexo is getting better but still doesn’t rival gravure for most customer reproductions. Flexo does compete with simple art, but cannot match gravure for high-end art.”

Magen adds, “Flexographic printing is second to gravure,” he says. “We recommend it mainly for short or one-time runs.”

So quality-wise, flexo is still in the rearview mirror, but cost-wise, going gravure means you’re going to pay for it. Kirchhoff says one challenge affecting gravure printers right now is “the need for rapid changeovers to accommodate smaller print runs with multiple SKUs.”

Wolk says, “Prepress (engravings) charges and lead times for cylinders are two of the biggest challenges for gravure printers. Flexo plates are much cheaper and can be turned around in days versus weeks.”

The bottom line

Gravure’s strength is its quality, which remains unmatched. Gravure printers are employing the flexographic process for certain customers and have determined that gravure and flexo each have a place in their businesses. Kirchhoff says, “We have seen marked improvement in flexographic printing quality and have recently installed a flexographic printing press, which allows us to supply high-quality printing for short runs more cost-efficiently.”

“Both gravure and flexo have niches in the packaging market,” says Wolk. “Volumes and quality expectations are key for what process will work for the end user.”

“Gravure is an optimum printing process for nationally recognized name brands with wide distribution,” adds Kirchhoff. “In addition, gravure is an excellent process to utilize for pharmaceuticals due to the additional amount of patient information that must be conveyed on the packaging.”

In the end it all comes down to quality. “Gravure is the hallmark of quality,” says Magen. “As much flexo printing as we do, it’s hard to imagine some of our pouches running on anything but gravure.” pP

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