Gravure

vs
Flex
O

23rd/June/2023 – 05th August 2023

Submitted By – Annu
Submitted To: Nikhil Kumar
Popli Graphics Pvt. Ltd Sandeep
 Guru Jambheshwar University of
Science & Technology

Industrial Training Report on

Flexography vs Gravure

Submitted to- Submitted by-

Mr. Vikas Jangra Annu
(200030320058)
 Acknowledgements

We extend our heartfelt gratitude to all those who

have contributed to the successful completion of
this project titled "Gravure vs. Flexography." This
endeavour would not have been possible without
the support, guidance, and encouragement of
numerous individuals and institutions. Special
thanks to industry experts and professionals who
provided valuable insights. Collaboration with
colleagues and organizations contributed to the
development of this presentation. Their expertise
and support are greatly appreciated.
Gu
Contents-
Introduction
 History of Gravure and Flexography
 Gravure Printing
 Innovations in Gravure Technology
 Flexography
 Types of Flexography process
 Innovation in Flexography Technology
Market
 Market share of Gravure
 Market share of Flexography
 Ink and Machine Market
Methodology
 Data collection
 Questionnaire content
 Online survey through LinkedIn
 Details of Industrial Visits and observations
Result and Analysis
Conclusion and Recommendations
References
INTRODUCTION
Purpose:
The purpose of this research project is to conduct a comprehensive comparative
study of flexography (flexo) and gravure printing methods. By examining their
respective strengths, weaknesses, and applications, this study aims to provide
valuable insights for professionals and stakeholders in the printing industry. The
project seeks to address the question of which printing method is better suited
for specific printing requirements, based on factors such as print quality,
efficiency, sustainability, and economic considerations.

Context:
In today's fast-paced and technologically driven world, the printing industry
remains a crucial conduit for communication, packaging, and artistic
expression. Flexo and gravure printing have long been stalwarts of this industry,
each with its own historical evolution and specialized areas of application. This
project acknowledges the historical legacy of gravure, which dates back to the
late 19th century, and the adaptability of flexo, which has seen significant
advancements in recent decades. By placing these methods in the context of
modern printing demands, materials, and environmental considerations, the
project recognizes the need to assess their continued relevance and potential
innovations.

Significance:
The significance of this project extends to multiple facets of the printing
industry and beyond. For printing professionals, the comprehensive comparison
of flexo and gravure offers a valuable resource for selecting the most
appropriate method for diverse projects, optimizing print quality, cost-
effectiveness, and production efficiency. Additionally, the project contributes to
the broader discourse on sustainable printing practices, as both flexo and
gravure have implications for resource usage and waste generation. By shedding
light on these aspects, the research aims to inform more ecologically conscious
decision-making within the industry. Furthermore, this project has the potential
to influence future technological advancements, inspire innovative approaches
to printing, and enhance our appreciation of the intricate processes that bring
visual and textual content to life on a variety of materials.
History of both process:-

Gravure-
 Gravure printing was invented sometime in the early 1890s by a man
from Czechoslovakia named Karel Klic.
 The process did not become widespread until the early twentieth century.
 W H Fox Talbot mentions in 1852, the use of a textile in the photographic
process to create half-tones in the printing plate.
 Collaboration between Klic and Fawcett in Lancaster resulted in the
founding of the Rembrandt Intaglio Printing Company in 1895, which
company produced art prints. In 1906 they marketed the first multi-colour
gravure print.
Flexography-
 In 1890, the first such patented press was built in Liverpool, England by
Bibby, Baron and Sons.
 The water-based ink smeared easily, leading the device to be known as
"Bibby's Folly".
 In the early 1900s, other European presses using rubber printing plates
and aniline oil-based ink were developed. This led to the process being
called "aniline printing".
 By the 1920s, most presses were made in Germany, where the process
was called "gummidruck", or rubber printing. In modern-day Germany,
the process continues to be called "gummidruck".
 in the 1940s, the Food and Drug Administrative classified aniline dyes as
unsuitable for food packaging and as a result, printing sales plummeted.
 In 1951 Franklin Moss, then the president of the Mosstype Corporation,
conducted a poll among the readers of his journal the Mosstyper to
submit new names for the printing process.
 The Mosstyper overwhelmingly chose the last of these, and "flexographic
process" was chosen
GRAVURE PRINTING
The term “gravure” refers to a printing process that involves engraving an
image onto a printing cylinder. The origins of a gravure printing can be traced
back to intaglio printing techniques that were developed in the 15th century
Father of gravure printing is Karl Klic.
Gravure printing is a high-quality, high-speed printing method. It uses engraved
cylinder to transfer ink onto substrate.
Principle: The printed elements will be engraved on the metal surface. When
the ink is brought to the surface of the, it then spills into the depression of the
printed elements.

Intaglio and gravure difference

Rotogravure (or gravure for short) is a type of intaglio printing process, which
involves engraving the image onto an image carrier. In gravure printing, the
image is engraved onto a cylinder because, like offset printing and flexography,
it uses a rotary printing press.
Intaglio printing allows for the reproduction of fine details, textures, and subtle
tonal variations, making it suitable for producing high-quality prints with a rich
and distinctive appearance.
Rotogravure printing is known for its ability to produce high-quality images at
high speeds, making it suitable for large print runs of magazines, catalogs,
packaging materials and more.
Innovations in the Gravure Technology:
Laser Engraving- Laser engraving technology has significantly impacted the
image carrier preparation process of gravure cylinders, offering numerous
advantages over traditional mechanical engraving methods. In the image carrier
preparation stage, the surface of the gravure cylinder is engraved with the
desired image or pattern, which will be used for printing.

Here's how laser engraving technology is applied in the image carrier

preparation of gravure cylinders:

1. Non-contact engraving: Laser engraving is a non-contact process,

meaning there is no physical contact between the laser beam and the cylinder's
surface. This eliminates the risk of mechanical damage to the cylinder, ensuring
a longer lifespan and reducing the need for frequent cylinder replacements.

2. Precise and fine detail: Laser engraving technology enables precise

control over the size and shape of the engraved cells on the cylinder's surface.
The laser beam can create extremely fine details and intricate patterns, allowing
for high-resolution image reproduction and improved print quality.

3. Flexibility in design: Unlike traditional mechanical methods, which may

require changing mechanical parts for different designs, laser engraving can
easily accommodate design changes. The digital nature of laser control allows
for quick adjustments and modifications to the engraving pattern, streamlining
the process for different print jobs.

4. Smooth gradients and shades: Laser engraving can create smooth

gradients and shades by varying the cell depths in a controlled manner. This
capability is essential for producing high-quality prints, especially in
applications that require reproducing photographic images or illustrations with
varying tones.

5. Reproducibility: Laser engraving technology ensures consistent and

repeatable results across multiple cylinders. Once a design is digitally
programmed, it can be replicated precisely on other cylinders, reducing
variations between prints and ensuring brand consistency.

ARC technology-
Automatic print registration control systems for detecting print registration
errors on rotogravure printing machines. The AlygnAXIS automatic print
registration control system corrects print and colour registration errors in
rotogravure printing processes. It helps in Precise, consistent, fast response

Taps layout System:-

TAPS is a truly unique feature – no other such system being available on the
market to date – which works by a single operator touch of the dedicated push-
button located on the main console. TAPS starts the press, moves all the
cylinders in register position and switches the register control into automatic
mode by reading a dedicated pattern printed on the web. The procedure is
completed in just a few minutes, whether it is a new or repeat job. One of the
advantages of the TAPS system is that it is unaffected by conventional pre-
register issues: it does not require any pre-register devices such as laser pointer,
pre-register rings, adhesive tapes or reading sensors for cylinder marks, and as
such it avoid any mistakes that might occur in the setting phase of those
devices.

TAPS is also unaffected by the web path configuration because it works even in
case of mistakes occurring during web threading, or by the sequence of printing
units. It also works with reverse printing. The excellent stability of the register
during acceleration and printing is due to the HDI (High-Dynamic-Interface)
function which is fitted on all ROTOMEC presses. The integration between the
ES and the REGISTRON register control enables the fastest corrections time,
even at the critical times of speed variations
Sleeve Technology-
Sleeve technology in gravure printing process refers to the use of flexible
sleeves made of compressible materials in the impression roller. The sleeve
technology has seen several innovations that have brought significant
advantages to the gravure printing process. Some of the key innovations
include:

 Quick Changeover
 Lighter and More Durable Materials
 Reduced Vibration and Noise
 Improved Print Registration.
 Enhanced Ink Transfer
 Digital Imaging and Engraving
 Lightweight Sleeve Solutions
 Environmentally Friendly Materials.

FLEXOGRAPHY PRINTING
Flexography, commonly known as "flexo," is a modern printing process that
originated in the early 20th century. In 1890, flexography is invented.
A flexographic print is made by creating a positive mirrored master of the
required image as a 3D relief in a rubber or polymer material. Flexographic
plates can be created with analogue and digital plate making processes.
PrinCIple: The image areas are raised above the non-image areas on the
rubber or polymer plate

Basic of the flexography printing process. -In flexographic printing, the

starting material comes in the form of a roll, which passes through a series of
rotary flexible relief plates. A specialized roller feeds each flexible plate with
ink, with a single flexible plate required for each individual printed colour. The
relief plates work in tandem to provide all colours for the final print product.

In cases where additional processes are required – such as laminating,

embossing or die-cutting – they can be integrated along with printing in a single
pass, greatly increasing production speed and capabilities over more traditional
printing methods.

Types of Flexography-
  Inline flexography

 Stack flexography
 CI flexography

Inline Flexography:

Inline flexography process is designed for single- pass printing directly onto a
substrate. In an inline configuration, the printing stations are arranged in a linear
sequence. Inline flexography is often used for label printing, flexible packaging,
and narrow web applications

Price Range-
 Entry level- $50,000 to $150,000.

 Mid-range-$150,000 to $500,000

 High-end- $500,000 to several million dollars.

Features of Inline Flexography-

 Single row configuration
 Arranged in a straight line
 Save space
 Reduce the overall footprint of the printing press
 Simplified Web Path

STACK FLEXOGRAPHY:
Stack flexography presses feature vertically arranged printing units, allowing for
easy access and maintenance. Each colour station is a separate unit stacked on top of
each other. Stack presses are commonly used for flexible packaging, corrugated
board, and other materials where print quality and colour registration are important.
CI FLEXOGRAPHY:
CI flexography presses are designed with a large central impression drum that
holds the substrate against the rotating plate cylinder. This configuration allows
for consistent contact between the substrate and the plate, resulting in precise
and high-quality printing. CI presses are commonly used for wide web
applications, such as flexible packaging, labels, and more
Price Range:
 Entry level: $200,000 to and $100,000
 Mid-range: $100,000 to $300,000
 High-end: $300,000 to $ 1 million or more

Features of Stack Flexography:

 Central impression drum
 High speed printing
 Wide web printing

Application of CI Flexography-
 Flexible Packaging
 High- volume printing
INNOVATION IN FLEXOGRAPHY TECHNOLOGY

Plate innovations-
In the flexography printing process, the plate image carrier is a cruCIal
component responsible for transferring the ink onto the substrate during
printing. Over the years, various innovations have been made in plate image
carriers, including analogue, thermal, and digital plate making methods.

Analog Plate Making

Thermal Plate Making

Digital Plate Making

Analog Plate Making: It involves a photographic process to transfer the

image onto the plate. Here's how it works:

a. Artwork Creation: The original image is created on a transparent film using

traditional graphic design methods or computer software.

b. Plate Exposure: The film is placed in contact with a

light-sensitive polymer plate (photopolymer or rubber),
which is then exposed to ultraviolet (UV) light. The UV
light hardens the plate areas exposed through the film,
creating the image on the plate.

c. Plate Development: After exposure, the unexposed areas of the plate are
washed away, leaving the raised image that corresponds to the printing
elements.
Thermal Plate Making-Thermal plate making is a more modern method
that improves upon the traditional analogue process. It involves using a thermal
imaging device to create the printing image on the plate. The steps in thermal
plate making are as follows:

a. Laser Imaging: The plate material is coated with a thermal layer. A laser
imaging device selectively heats the thermal layer, creating the printing
elements directly on the plate.

b. Plate Development: After laser imaging, the plate is processed to remove the
unexposed areas, leaving the raised image.

c. Plate Mounting: The thermal plate is mounted onto a plate cylinder or sleeve
for printing

Digital Plate Making: It involves using computer-to-plate (CTP)

technology to directly transfer the digital image onto the plate. The process
typically includes the following steps:

. Digital Prepress: The artwork is designed or converted into a digital format

using computer software.

b. Plate Imaging: A high-resolution CTP device exposes the plate material

directly using lasers or LED technology, bypassing the need for films or
intermediate steps.

c. Plate Development: The plate goes

through a development process to remove
the non-image areas, leaving the raised
printing elements.

SLEEVE TECHNOLOGY
A flexible, seamless, and thin sleeve made of compressible materials, such as
photopolymer or rubber, is slid onto the plate cylinder. The sleeve acts as a
carrier for the printing plate. Instead of mounting the plate directly onto the
cylinder, the plate is mounted on the sleeve. This allows for easy changeovers,
reduced downtime, and faster setup times between print jobs.

Anilox sleeve: Instead of traditional anilox rollers with heavy steel tubing,
integral headers and journals that take much longer to install or remove, the
anilox sleeve is mounted on a fixed air mandrel in the print station.

Forcing compressed air through holes in the air mandrel enables the anilox
sleeve to be mounted or removed in a matter of seconds. This allows for quicker
setups of new jobs or colour changes and especially provides a safer press
environment when handling due to the sleeve’s lightweight construction.

Sleeve-based
flexographic printing provides several advantages-

• Improved print quality

• Better registration
• Reduced vibration
• Increased press speed.
• Eliminates the need for plate tape
• Minimizes the risk of plate lift during printing.

ECG (Expanded colour gamut):

Expanded colour gamut (ECG) printing is an innovation in flexography that has
gained significant traction in the printing industry. ECG aims to extend the
traditional CMYK colour model by adding additional inks to achieve a broader
range of colours:

 Additional Ink Stations:

 Special ECG Colour Profiles

 Software and Colour Management Systems

 ECG Plate Technology

 Ink Formulations

 Improved Screening Technologies.

 Enhanced Press Control Systems

 Substrate Advancements

Benefits of Expanded Colour Gamut Printing in Flexography:

• Improved Colour Accuracy

• Reduced Spot Colour Usage inventory management.

• Better Colour Reproduction:

• Enhanced Print Quality

• Increased Efficiency
Hybrid printing:
Digital printing integration in flexography refers to the combination of
traditional flexographic printing with digital printing technologies to create
hybrid printing solutions. This integration aims to leverage the strengths of both
processes, offering enhanced flexibility, cost-effectiveness, and efficiency.

 Variable Data Printing (VDP).

 Shorter Print Runs and Quick Turnaround

 Colour Consistency

 Reduced Inventory

 Inline Finishing

 Variable Web Width

 Automated Workflows

 Data-Driven Printing

 Test and Prototyping

THE MARKET SIZE & SHARE
GRAVURE MARKET:
Global market share of gravure-
Market Size in 2022: In 2022, the gravure printing market was worth USD 3.7
billion.

Projected Market Size by 2030: The market is expected to reach a substantial

size of USD 6 billion by the year 2030. This represents a significant increase in
market value over the period from 2022 to 2030.

Compound Annual Growth Rate (CAGR): The compound annual growth

rate, or CAGR, is an important metric in market analysis. In this case, the
CAGR is stated as 6.4% over the period from 2022 to 2030. This indicates that
the market is expected to grow at a steady rate over this eight-year period.

2023 Market Size: The market size for 2023 is estimated to be 4.082USD
billion, based on the information provided.
FLEXOGRAPHY GLOBAL MARKET:
Market Size in 2023: In the year 2023, the Flexographic Printing Market is
estimated to be worth USD 190.28 billion. This figure represents the total value
of the market at that point in time.
Projected Market Size by 2030: The market is expected to experience growth
and reach a value of USD 221.95 billion by the year 2030. This projection
indicates an increase in the total market value over this seven-year period.
Compound Annual Growth Rate (CAGR): The Compound Annual Growth
Rate, or CAGR, is a metric that measures the average annual growth rate of the
market within a specific timeframe. In this case, the CAGR is stated as 3.13%
during the forecast period, which spans from 2023 to 2030. This
percentage represents the expected annual rate of increase in market
value.

At present, the compound annual growth rate of the Asian flexography

printing market is 4.3%, followed by 3.4% in Eastern Europe
and 2.0% in Latin

GLOBAL MARKET FOR FLEXOGRAPHIC PRINTING

USD 221.95 Billion

USD 190.28 Billion

2023 2030
FLEXOGRAPHY INDIA MARKET:
The flexography market is increasing rapidly in India, The of Growth market in
printing labels, cartons, and flexible plastics.

Market Size in 2022: In 2022, the Flexographic Printing Market was valued at
$5.35 billion. This represents the total worth of the market at that time.

Market Size in 2023: It's projected that the market size increased to $5.70
billion in 2023. This indicates that the market experienced growth within one
year.

Compound Annual Growth Rate (CAGR) from 2022 to 2023: The market's
growth rate from 2022 to 2023 is calculated as 6.6%. This represents the annual
rate of increase in market value during that specific year.

Future Projection for 2027: Looking ahead to 2027, the market is expected to
continue growing. It's projected to reach a size of $7.10 billion by that year.

CAGR from 2023 to 2027: The anticipated average annual growth rate for the
market between 2023 and 2027 is estimated at 5.6%. This indicates the
expected annual rate of increase in market value during this four-year period.

Ink Market of Gravure and Flexography-

The Global Gravure Printing ink market is estimated to be
increased at a rate of 4.3% during the period 2023-2031.

The Global Flexography Printing ink market is estimated to

be increased at a rate of 5.7% during the period 2023-2030.
Machine Market of Gravure and Flexography-
The machine market of Gravure technology will be increasing
at a CAGR of 3.8% from 2023 to 2030

The machine market of Flexography printing technology will

be increasing at a CAGR of 5.6% from 2023 to 2030 to be
reached 7.1 billion.
METHODOLOGY

In- Depth Company Discussion Data Conclusion

Visit Analysis
study

Data collection
The data collection will be carried throughout face to face interview with
company worker, manager and the owner of the company involved in the
flexography vs. gravure industry. A prior appointment will be made to ensure
the availability and willingness of participation to provide information.
The data collection is also taken from some of the internet website and LinkedIn
connections.
Questionnaire content
The interview questionnaire included the following sections:
Company Profile:
 Name and Address of a company
 Type of method you are using for manufacturing/ Converting operations
 Machine type Automatic & Semi- Automatic
Open closed ended question:
 Why are people in India preferring Gravure over flexography? What are
the reasons?
 What are the challenges we are facing in Gravure and flexography
Printing and packaging industries?
 Waste production is more in which process (Gravure & flexography)?
 What are the jobs, we can shift from gravure to flexography?
 What are the emerging technologies and innovations impact the industry?
 What are the main risks and uncertainties faced by companies in
industry?
 The substrate cannot be printed by gravure and flexography process?
 What are the main products and services are offered by companies in the
industry?
 Which are the jobs that have printed by both the process?
  Do you shift from gravure to CI flexography in the future?
 What are the substrate that can be printed by CI flexography but not by
the gravure and vice versa
 What are the new innovations that can be add in the future in both the
process?
Market question:
 Which printing process will be leading process after a Decade?
 What is the current size and growth rate of the industry?
 How a consumer behaviour and demand changing within the industry?
 According to you what is the percentage use of flexography and Gravure
in the market?
 Growth rate of both the processes?
Online survey through LinkedIn:
DETAILS OF INDUSTRIAL VISITS
We visit new places, we can learn about different cultures, industries, and
gaining insights into the world's diversity. Interacting with people during visits
allows us to exchange ideas and learn from their experiences. The visits play
vital role in the project, different companies teach us different things, we have
seen lot thing like printing machine, inks, and substrate. The company we have
visited in Near Delhi NCR, the companies are:

1. PRAKASH SHRINK PACK INDIA PVT. LTD.

2. VEE KAY INDUSTRIES
3. ARIHANT PACKAGING
4. WONDER PAC
5. ANUJ ENTERPRISES
6. SANJIVANI PACKAGING
PRAKASH SHRINK PACK INDIA PVT.LTD.

Prakash Shrink Pack India, have been one of the leading manufacturers
of Printed Shrink Labels and BOPP Wrap around Labels. The roots of Prakash
Group dates back to the year 1983. Back then, we were engaged in
manufacturing of wide length tarpaulin (up to 20ft width) with a production
capaCIty of 200 tons per month. With a vision to add one more dynamic chapter
in the history of labelling industry, we started with the manufacturing of high-
quality Multi-coloured Shrink Sleeves and BOPP Wrap around Labels.
Machine: Pelican solo mark 6450 (Gravure)
Machine size: 1300 mm
Machine speed: 250 Mpm
Colour units: 8 units
Web tension range: 30 TO 400NB
VEE KAY INDUSTERIES
Vee Kay Industries is a famous flexography company located in Kundli, Delhi.
The company is known for its expertise in producing high-quality printed
materials using this versatile and cost-effective printing technique. Vee Kay
Industries serves a wide range of industries, including packaging, labeling, and
various other commercial applications.
Machine: Bobst (Master M5) (flexo)

Machine size: 370 mm

Machine speed: 120Mpm

Colour units: 10 units

ARIHANT PACKAGING
Arihant Packaging is a gravure printing company located in the Wazirpur
Industrial Area. Arihant Packaging specializes in high-quality gravure printing
services. Their expertise lies in producing visually appealing and durable
packaging materials, such as flexible packaging, labels, and wrappers. With a
commitment to innovation and customer satisfaction,
Machine: Rotomac

Machine size: 900mm

Machine speed: 200Mpm

Colour units: 7 units

Printing cylinder repeat range: 450-920 mm

WONDER PAC
"Wonderpac", are one of the prominent manufacturers and exporters of an
exclusive range of Labels and Holograms. Offered range if inclusive of Prime
Labels, Wine Labels, Personal Care Labels and Filmic Labels. Our products are
functionally competent and are manufactured using advanced technology and
superior raw materials. We are offering Printing Services to our client. We are
exporting our quality products in all over the Globe.

Machine: Mark Andy 2200 (flexo)

Machine size: 330 mm

Machine speed: 150 Mpm

Colour units: 08 units

Printing cylinder repeat range: -178 - 610 mm
ANUJ ENTERPRISES
Anuj Enterprises is a flexography company located in the industrial hub of
Bawana. Specializing in flexographic printing, the company offers a wide range
of high-quality printing. With a strong commitment and customer satisfaction,
Anuj Enterprises has established itself as a trusted partner for businesses
seeking top-notch flexographic printing services in the Bawana area.

Machine: Mark Andy Cosmo 2004 (flexo)

Machine size: 457 mm
Machine speed: 100Mpm
Colour units: 09 units
Printing cylinder repeat range: -168 – 600 mm
Observation throughout all Visits-
We learned a lot about machines, ink, quality, substrates, and the
market after seeing all these businesses.
The design of the product, which features more solid colours, leans
more toward CI flexo. However, there are more half-tone prints on the
product; although most consumers still like gravure, CI flexo are
quickly developing. Now, it can compete with the gravure-printed
halftone print. Due to the use of water-based ink, CI flexo rivals
gravure in speed and is furthermore hygienic. From a few microns to
many microns, CI Flexo can print. With CI flexo, we can easily print
cartoons on 120 gsm paper and 6 micron film. Consequently, several
of these switch to flexo.
From visiting Sanjivini Graphics to Prakash shrink pack companies,
we observed how much innovation has happened in gravure. In the
first, the machines are fully manual, but in the Prakash, highly
advanced, fully automatic machines were present.
Flexo has more innovation now, so we see many things for labour
costs, cost reductions, and time savings. As these operations become
more automated, they are moving toward one-man presses. They use
chilled water inside the roll and swift task switching just for
continuous operation and time savings. With the aid of ECG, they
quickly switch jobs and attach distinct merely shifts. They only need
to alter the ratio of these colours; they don't need to alter the colour
from the ink tray.
Less micron of LDPE cannot be printed by the gravure process.
However, CI flexography can easily print on the LDPE and provide
the best quality on the LDPE substrate.
In flexography, now instead of UV lamps, they are using LED lamps
due to the longer life of LED lamps, and in the case of UV lamps,
more cooling is required.
Result and Analysis

According to market, the CI flexography will be leading in the future by

2030.There are various reason for its popularities and increased demand due to
flexibility, innovations and universal applications.

The gravure printing industry, like Huhtamaki PPL, Uflex, Shrinath Rot pack,
Amcor, Constantia India, and UMAX, are making significant investments in CI
flexo presses. This is a major shift in how they approach printing technology.
They are actively choosing CI flexo for certain printing jobs, especially those
that involve large solid areas and high-quality graphics, including reverse
printing. This shows that CI flexo is becoming the preferred choice for specific
types of printing, which can influence other companies in the industry to do the
same.
CI flexo offers cost advantages, especially when companies need to print a
small number of items for flexible packaging. The savings in making the plates
(the parts used for printing) for CI flexo can be as high as 15%.

Market by 2030

Flexography
Gravure

Moreover, making flexo plates is much faster and more efficient than engraving
gravure cylinders. Flexo plates can be produced in a matter of hours, while
gravure cylinders take much longer. These cost savings are attractive to
companies looking to make their production processes more efficient and cost-
effective.

Recent improvements in CI flexo technology have made it capable of producing

high-quality printing results that are just as good as those from gravure printing.
CI flexo isn't limited to specific materials; it can print on a wide range of
surfaces, including polyethylene (PE), biaxial-oriented polypropylene (BOPP),
and polyester structures. This versatility makes CI flexo a flexible choice for
various packaging needs, meeting the diverse demands of the industry.

The companies that make CI flexo machines, like Comexi, Soma, Windmöller&
Hölscher (W&H), Uteco, and Bobst, are well-known and respected in the
industry. They offer advanced and reliable CI flexo machines, giving printer’s
confidence in the quality and performance of their equipment. Knowing they
can rely on these machines is a crucial factor in why CI flexo is gaining
popularity.
Major Brands are Switching: Recognizable brands such as Unilever, Procter &
G Major Brands are Switching: Recognizable brands such as Unilever, Procter
& Gamble (P&G), Prima, CBL, Lalan, Kimberly-Clark, SC Johnson, and
Reckitt Benckiser (known for products like Dettol and Lysol) have switched
from gravure to CI flexo for their printing needs.

They've made this transition because CI flexo not only helps them save money
but also produces attractive and high-quality results. These major brands set an
example of a successful shift to CI flexo, which can inspire other companies to
do the same. In simple terms, CI flexo is becoming the preferred choice for
certain printing tasks because it's cost-effective, produces high-quality results,
and is backed by trusted manufacturers. Leading printers and major brands have
already made the switch, making CI flexo a compelling option for others in the
industry to consider.

Here is some of the substrate that they are used in CI flexo but not in Gravure:

 PE Foam
 Tissue Paper
 Uneven Surface
 Corrugated Board
 LDPE (6 micron)

Reason why CI flexography is growing more than Gravure-

 Stretchable film- Stretchable film is better printed by CI Flexography
than gravure like LDPE can be printed better by CI flexography.
 Efficiency- CI flexography press can run at a speed of 350m/min to
500m/min, while rotogravure can only run at a speed of 120 to 200m/min
when handling stretchable film.
 Register precision-The web path for one flexography unit is 0.4m to
0.6m, while web path for one rotogravure unit is 4m to 6m. Taking LDPE
film as example, the flexo qualified rate is 5% to 10% higher than that of
rotogravure. Generally, the flexo register can reach 0.1 to 0.2mm, while
Some Europe brand can reach 0.05 to 0.08mm. The rotogravure register
can only reach 0.3 to 0.5mm.
  Energy consumption- Energy consumption by flexo is lower than
rotogravure, regardless steam heating or electrical heating
 Ink consumption- the flexo printing applies thinner ink than rotogravure
printing does. Therefore, flexo consumes less ink than rotogravure.
Another important factor is that flexo has closed ink chamber, which
reduces the volatilization to the maximum extent. Compared to the
rotogravure with open ink chamber, flexo ink consumption is 40% to
50% less than rotogravure.
 Consumables- Rotogravure printing adopts single blade with heavy
pressure, while flexo printing adopts double blades with light pressure.
Therefore, flexo consumes 30% blades less than rotogravure does.
However, flexo adopts 0.55mm double side adhesive tape for plate
mounted to sleeve, while rotogravure does not need adhesive tape.

CI Flexo User’s in India & Delhi NCR

 As both the market statement states that, In the upcoming year, the
growth of flexo will increase as compare to Gravure because of CI Flexo.
 The rate of change in market is increasing by 2x, people in the industry
are getting to know about the CI Flexo, most of the big printing industry
are started setup the CI flexo, like Huhtamaki PPL, Uflex, Shrinath
Rotopack, Amcor, Constantia India, and UMAX. These companies are all
over in India.
 In Delhi NCR the companies like SB packaging, Uflex, Bhatia & Sons,
GLS Groups DJS Printers OM Flex are using CI Flexo.

CONCLUSION AND RECOMMENDATIONS

In conclusion, the printing industry is pointing firmly toward CI (Central
Impression) flexography technology. This conclusion is based on several things;
Prominent gravure printers in the subcontinent have recently invested in CI
flexography presses, signalling a significant shift in their approach to printing
technology. The fact that industry leaders are actively choosing CI flexography
for specific applications indicates its growing preference and acceptance. The
ban on toluene, a component of solvent-based inks, in Europe underscores the
industry's move towards more sustainable and environmentally friendly
practices. CI flexography, with its use of water-based inks, aligns perfectly with
these evolving regulations and sustainability initiatives.CI flexography offers
cost efficiency, rapid plate production, improved print quality, and versatility.
These benefits make it an attractive choice for various printing needs.

CI flexo gives better results than gravure but only for one material whereas
gravure has universal applications.“The quality of printing on plastics is best
achieved by gravure but for certain applications such LDPE which is
stretchable is nature, CI flexo achieves better results as the film is supported
throughout the impression cycle. Similarly for uneven surfaces such as woven
sacks, flexography offers better solutions. With the restrictions in usage of
multi-layered films, more and more PE based structure is coming leading to
popularity of CI flexo .

Flexography has outperformed the gravure market in a number of ways

adaptability to modification, versatility, sustainability initiatives, and
technological developments. While gravure is still useful in some high-
resolution printing applications, flexo has gained an advantage and taken a
leading position in the packaging, labels, and other market.

Due to its combination of high-quality printing, efficiency, sustainability efforts,

and adaptability to changing trends, CI Flexo is well-positioned to dominate the
printing industry in the future. CI flexo is well-positioned to play a crucial part
in satisfying these shifting needs as the demand for flexible packaging,
personalization, and environmentally friendly printing techniques continues to
expand, both in existing and emerging markets.

RECOMMENDATION
I highly recommend considering SOMA CI (Central Impression) flexo
technology as an excellent choice for the market. Several compelling reasons
support this recommendation; SOMA has established a strong reputation for
producing high-quality and reliable CI flexo machines. Their track record in the
industry speaks to their commitment to excellence and innovation. Leading
players in the printing sector, including gravure printers in the subcontinent,
have already made strategic investments in CI flexo presses. This underscores
the trust and confidence they place in the technology, particularly from
respected manufacturers like SOMA. CI flexo technology, when backed by
manufacturers like SOMA, offers the versatility to handle a wide range of
substrates and printing requirements. It is capable of delivering outstanding
print quality, making it suitable for various applications, including those with
large solid areas and high-quality graphics.

References
 Mentors:
Mr. Sanjeev Popli (Director at Popli Graphics Pvt. Ltd)
Mr. Rahul Yadav (Service Incharge at Popli Graphics Pvt. Ltd.)

Mr. Gaurav Sharma(Sales Manager at Popli Graphics Pvt. Ltd.)

Mr. Nitin Sharma(Sales Executive at Popli Graphics Pvt. Ltd.)

 Visited industries
PRAKASH SHRINK PACK INDIA PVT. LTD.

VEE KAY INDUSTRIES

ARIHANT PACKAGING

WONDER PAC

ANUJ ENTERPRISES

SANJIVANI PACKAGING

 By LinkedIn
Mr. Muralidhar Nalli
(CEO at Digiflex,TGS India, MR Solutions Flexo*Corrugation*Offset Gravure)

Mr. Rohit kumar

(CI Flexo and Roto Gravure printing SpeCIalist {W&H (Miraflex), (Cerutti,
Rotomec)

Mr. Umesh Thorat

(Printing Department Incharge at Dot Propack industries Pvt. Ltd.)

Mr. Pritham kumar(Indian Institute of Packaging IIP)

Online links-
https://www.printweek.in/features/the-gravureisation-of-india-
packaging-market-with-pelican-42958
https://www.maximizemarketresearch.com/market-report/global-
rotogravure-printing-machine-market/53728/
https://www.researchandmarkets.com/reports/5302336/gravure-
printing-global-strategic-business
https://www.maximizemarketresearch.com/market-report/global-
packaging-printing-market/22799/
https://www.transparencymarketresearch.com/gravure-printing-ink-
market.html
https://www.mordorintelligence.com/industry-reports/flexographic-
printing-market
https://www.maximizemarketresearch.com/market-report/global-
flexographic-ink-market/31279/
https://finance.yahoo.com/news/central-impression-type-flexographic-
printing-150000110.html
https://www.researchandmarkets.com/report/flexographic-printing
https://www.printweek.in/news/packaging-boost-to-gravure-printing-
inks-market-42837
https://www.printweek.in/features/life-cycle-assessment-flexographic-
printing-and-platemaking-update-55532
https://www.linkedin.com/pulse/flexo-vs-gravure-cost-flexible-
package-hailun-yao%3FtrackingId=AVDEv
%252FXYR7WAGGS2MlrkGw%253D%253D/?trackingId=AVDEv
%2FXYR7WAGGS2MlrkGw%3D%3D
Thank You