GRAVURE vs. HIGH QUALITY TONE FLEXO - CONCLUSION

FLEXO vs. GRAVURE COSTS

"In evaluating the data, it is obvious that the first time costs of rotogravure are more costly than the cost of flexo.

What is sometimes less obvious, is the real cost of the two processes, when compared over the life of the job. In evaluating the two examples, it's evident that in "Example A" the cost of flexo vs. rotogravure is equal after two production runs. In the case of "Example B", the break-even point is reached after just the first production run. So, when looking at the real cost, there is quite a potential savings in pre-press cost for rotogravure, when products are re-run multiple times throughout the year.

In evaluating the costs of various printing process for the packaging industry, it's important to evaluate the costs based upon the repeat runs that are common for many packaging products and not just the initial cost associated with the pre-press.

Aside from the pre-press costs, printers should also consider some of the other advantages of rotogravure:

  » Easily attainable and repeatable process printing.
  » Availability of printing the brightest metallic and fluorescent inks.
  » Ease of handling lightweight films at high speeds with tight register control.
  » The ability to create reverse printed laminated labels in-line.
  » The high efficiencies associated with low cost gravure inks and high running speeds.
  » Color consistency throughout the press run."

Dick Chesnut
President
W. R. Chesnut Engineering, Inc.