One of the first technical questions when ordering printed packaging is: “Will this job be printed in rotogravure or flexo?” Both methods are widely used in flexible packaging, but their cost structures, print characteristics and ideal job types differ. This article summarizes the differences in plain language.
What is rotogravure printing?
In rotogravure, the image is engraved onto the surface of a metal cylinder. Micro-cells on the cylinder carry the ink and transfer it directly to the film. A separate cylinder is prepared for each colour.
Key characteristics:
- Photo-quality, highly detailed images with smooth gradients
- Colour consistency across long print runs
- Durable cylinders; the same design can be reprinted again and again
- Higher initial setup (cylinder) cost
What is flexo printing?
In flexo, the image is transferred onto flexible photopolymer plates. The plates are mounted on cylinders for printing.
Key characteristics:
- Lower setup cost than rotogravure
- Adapts more quickly to design changes
- Modern flexo technology delivers sharp, vibrant results
- Very efficient for solid-colour, graphic-based designs
Which should you choose, and when?
| Criterion | Rotogravure | Flexo |
|---|---|---|
| Image type | Photos, gradients, fine detail | Solid colours, logos, graphics |
| Design frequency | Stable, long-lasting designs | Frequently changing designs, campaigns |
| Setup cost | Higher | Lower |
| Long-run consistency | Very high | High |
In short: if your brand will use the same design for years and you want a premium look on the shelf, rotogravure has the edge. If you have multiple SKUs, seasonal designs or a lower starting budget, flexo is often the smarter choice.
Factors that affect cost
With both methods, setup cost is directly linked to the number of colours: each colour means a separate cylinder or plate. The size of the artwork and the ratio of matte to gloss areas also affect setup cost. Keeping the colour count deliberate when designing can significantly reduce total cost.
Printing capacity at Porpack
At Porpack we print with both methods on our 6-colour flexo and 8-colour rotogravure presses. This lets us choose the right method for your design and budget together.
Not sure which method suits your product? Send us your design and our technical team will review it. Get a quote →