Flexo vs. gravure in packaging printing - European Rotogravure ...

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Oct 12, 2006 ... Stuttgart (Technology Centre of the. German Flexo Technical Association), designated Scientific Leader. • Experience: 22 years in printing ...
ERA – European Rotogravure Association Packaging Conference 11-12 October 2006, Osnabrück, Germany

Flexo vs. Gravure in Packaging Printing

Dr. Martin Dreher – DFTA-TZ, Stuttgart

Disclaimer •

• •

Please mind that the version of this presentation at hand had to be composed at a point in time when some important input data may have not yet been available. Therefore, this presentation may not reflect the latest known status of the subject. Please check for potential later versions under www.dfta-tz.de or contact the author directly under [email protected].

Speaker • •

Name: Position:



Experience:



Job Tasks:



Mission:

Dr. Martin Dreher Assistant Manager of DFTA-TZ, Stuttgart (Technology Centre of the German Flexo Technical Association), designated Scientific Leader 22 years in printing industry: apprenticed litho pressman, >16 years of work in Flexo, >20 years of observing Gravure and others Training, education, technical assessments, technical developments, presentations, etc. advancing and enhancing packaging printing (1)

(1) holding what is probably the last fundamental printing patent about a hybrid system between Gravure and Flexo, later in this presentation to be referred to as a „Hybrid Printing Method“

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing

Preface •





Some of the following pieces of information have been derived from other than my own sources. They have been marked accordingly. Such information will be passed on as direct as possible, i.e. some data had to be generalised or anonymised because the underlying studies and calculations contained information that was private to the sender. I will give my personal ratings and comments about such data as direct and unbiased as possible.

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing

The Technical Status Quo

Gravure

Flexography

Lithography



Lithography and other printing methods to be set aside here.



Both Flexo and Gravure have their particular strengths and weaknesses. The following review relates to the respective characteristics as they are perceived in packaging printing.



Flexography´s Strengths • • • • • •

Less expensive process Versatility in substrates Flexibility due to exchangeability of parts of the print design Easy and simple plate making Good sharpness of bar codes, type and linework Best revolution-to-revolution registration even with thinnest substrates due to CI presses

Flexography´s Weaknesses • • •

Increasing cost due to growing quality demands in Anilox rollers, printing inks, printing forms, tapes, etc. Limitations in Packaging Design Sporadic limitations in print quality due to: – – – –

Squeezed ink Lack of coverage in solids High dot gain Insufficient uniformity of print production

Gravure´s Strengths • • •

Simple schematic of printing presses Any (odd) repeat length Typically very good print quality in images

Gravure´s Weaknesses •

plate making is demanding due to: – treatment of metals – handling of massive metal cylinders – limitations in imaging systems, etc.

• •

Lack of flexibility due to long delivery times and missing exchangeability of design elements Uniformity and repeatability quite demanding (larger impact of substrate surface characteristics than in Flexo)

• •

Limited sharpness of type and linework Registration concerns with flexible substrates (revolution-torevolution)



Characteristics of Flexo & Gravure From: „Gravure vs Flexo - Cost Comparison“, PLGA

FLEXO

GRAVURE



Solids and process may need to be separated



Ability to print solids, type and process on the same print station



Limitations in reverse and fine type work (improvements due to C to P and DD technology)



Ability to print fine type and line work (further improved via laser technology) down to 1 point text.



Can print up to 150 lpi



Can print process work up to 250 lpi



Closed solids need correct combination of plate, tape and ink



Can produce rich colors in solids and achieves excellent brilliancy



Due to plate elasticity and tolerances, reproducibility is largely dependent on prepress conditions and operator skill.



Excellent reproducibility, largely independent of operator skill



My Conclusions and Ratings on the Technical Aspects • • •

I do agree with some of the above statements (see markers). However, I do strongly oppose the overall notion of these statements! Neither is Gravure that advanced overall, nor is Flexo that handicapped on average!

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing

Flexible Packaging by Process and Region North America $175MM

Gravure 23%

Flexo 75%

Europe $240MM

Gravure 41%

Flexo 57%

Asia Pacific $132MM

Gravure 85% Flexo 10%

South America Gravure 18% $49MM

Flexo 82%

Flexo dominated Global Print Form Market $595MM

Gravure dominated Source: Courtesy of DuPont Cyrel®

Market Share Interpretations •





Flexo drastically outnumbers Gravure in North America and South America. Gravure is the „underdog“, hence the aforementioned aggressive statements. In Asia, Gravure is almost unrivalled in its market share and standing. However, that has been sponsored in the past by environmental legislation being less harsh than in EU and the Americas which enabled less expensive, but more hazardous plate making techniques (etching) to be used. In Europe, Flexo enjoys the largest market share, but is being challenged by Gravure constantly.

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing



In Summary: Advantage Flexo

Advantage Gr avur e

-60%

-40%

-20%

Advantage Fle xo 0%

20%

40%

60%

80%

100%

120%

140%

160%

180%

200%

220%

240%

260%

XXXXX

Gravure vs. Cyrel® round

XXXXX

Gravure vs. Flexo

XXXXX XXXXX XXXXX XXXXX

XXXXX XXXXX XXXXX XXXXX XXXXX

XXXXX XXXXX XXXXX XXXXX

Source: Courtesy of DuPont Cyrel®





Summary of Press Related Cost Factors

• Compact design of Flexographic Central Impression Cylinder press: – – – –

Less capital investment Less labour cost Lesser floor space requirements Lesser energy requirements

• => Advantage of Flexo over Gravure • => Very large advantage of Cyrel® round over Gravure

“ Source: Courtesy of DuPont Cyrel®



Print Forms: Typical Prices

Where does Hell Gravure´s Cellaxy sort in ?

Gravure Cylinder: Imaging incl. Copper plating and Chrome plating (raw cylinder not included!)

€ 250 - € 1100

Flexo: Silicone Rubber direct Laser engraving (incl. Sleeve)

~€ 980

Flexo: Rubber direct Laser engraving (incl. Sleeve)

~€ 800

Cyrel® Flexo Fotopolymers ~€ 850

Cyrel® round Cyrel® - Plate-on-Sleeve (inc sleeve)

~€ 500 - € 800

Cyrel® - Plate on Sleeve -adapter mandrel (incl. mounting)

~€ 440

Cyrel® - digital – plate on steel cylinder (incl. mounting)

~€ 350

Cyrel® - analog – plate on steel cylinder (incl. mounting)

~€ 250

Thin walled mylar sleeves, no composite, no bridge mandrels

Western Europe, €/m² Typical sizes: ~ 0.4 to 0.6 m² Source: Courtesy of DuPont Cyrel®

0

200

400

600

800

1,000

1,200

1,400

1,600





Why this Large Range of Prices?

• Plate Making fixed costs: – Gravure: approx. > 80% – Flexo: approx. 60%

• Capacities with high fixed cost drives prices and cost: – Gravure cylinder makers must use their capacities (at any price) – Expansions of capacity are costly (large capital investment)

• Cost of Flexo Plate Making: high portion of variable cost – Flexo plate makers may expand and reduce their capacity more freely – Flexo is more flexible and open for innovation

Source: Courtesy of DuPont Cyrel®





Summary of Variable Costs

• • •

Printing forms: comparable Substrate waste: advantage Flexo Printing inks: advantage Flexo



=> Small advantage of Flexo over Gravure

Source: Courtesy of DuPont Cyrel®



My Conclusions and Ratings on Cost Aspects • •

• •

I do agree with most of the above statements. However, in that some of the perceived cost benefits that Flexo enjoys over Gravure, are being based on the use of the („costly“) Cyrel® round seamless sleeves, it must be noted that the production capacities available for them in the EU market are currently insufficient for satisfying larger market demands (as is the case with direct Laser Engraving of Gravure cylinders). Hence, such cost comparisons reflect only a small niche of the market. The lion´s share of the packaging printing market will need to be compared upon the basis of electromechanically engraved Gravure cylinders vs. digitally imaged Flexographic fotopolymer plates (then giving Flexo a somewhat smaller, yet noticeable cost advantage).

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing

Digitally Imaged Fotopolymer Sleeves •

Digitally imaged Fotopolymer Flexo sleeves on the rise!



Some of the printing related advantages are ☺ ☺ ☺ ☺



short make-ready seamless designs higher press speed possible substrate savings

No plate mounting ☺ cost savings in personnel and machines ☺ time savings ☺ no mounting tape cost



New technical opportunities ☺ alternative halftone screens with less patterns and less mottling through excellent registration (first time and continuous)



Cost of raw material is substantially higher than with plate materials, but will be more than compensated for by the aforementioned benefits.

Laser Engraved Gravure Cylinders •



Laser engraving has been around for quite some time, but Hell Gravure Systems´ Cellaxy is about to re-heat the debate due to its capability of using Copper as a medium again. Benefits should be ☺ Plating process may remain unchanged ☺ Very high engraving speed ☺ Versatility of engraving better structures



Aspects that remain to be seen are Cost of ownership and running Reliability



Certainly a very interesting new alternative to look at.

Halftone Screening •

Advantage of Flexo over Gravure due to Flexo´s superior registration quality of CI presses => Flexo may use new screening alternatives, which require good registration and, given that, may yield – – – –

sharper printed pictures with much less halftone-related structures and a standardisation in screen angles, coupled with production safety through much less sources of error.

„Plastics“ as Gravure Print Forms •







It has been attempted repeatedly to use high-tech and highvalue plastics (in particular some Polyamides) for plate making in Gravure, thus trying to avoid the costly, environmentally critical and time consuming copper (or zinc) plating process. None of the attempts has yielded a product that enjoyed noticeable market penetration so far. However, some trials are still in process. Hence, whether or not such high-tech plastics will be successful in replacing metals remains to be seen. I personally believe in the „flexible Gravure form“ approach, i.e. using elastic materials, which do open up a whole new line of thought ...

Hybrid Printing Method • •

Working title used to be „Helioflex“*, reflecting the combination of Gravure and Flexo Soft and elastic printing plate – – – – – – – –



Plate making through fotopolymerisation (exposure!) feasible, utilising Flexo printing plate materials Special doctoring system plate making preferably with Flexo plates or seamless sleeves Imaging with special Gravure-adapted positive (vs. negative) colour separation plate making even easier and cheaper than in Flexo due to shallow relief High definition of type and linework with autotypical imaging methods (film or platesetters) Rasterisation methods of Flexo applicable Optimum ink transfer - ink is squeezed out of cells through elasticity

Building a CI Gravure press is feasible * this title has been brand protected by Hell Gravure Systems later and therefore must not be used any more, but older documents may still refer to the process under this name

Digital Printing Methods • • •

We have a saying in the German language: „Wenn zwei sich streiten, freut sich der Dritte.“ (If two struggle with one another, a third party is happy.) Hence, if Flexo and Gravure struggle with one another, will Digital Printing be the happy winner? What are the benefits that Digital Printing can claim? ☺ No plate making times and cost factors ☺ Design change flexibilities



Disadvantageous factors are: Limited applicability (sizes, substrates etc.) High cost (specially treated substrates, costly inks, etc.)



My personal conclusion: Digital printing methods will have to go a very long way before they may challenge conventional methods in more than isolated market niches! Digital printing will be complementing conventional methods for quite a number or years to come.

Flexo vs. Gravure in Packaging Printing • • • • • •

Intro and Preface Technical aspects – What makes Gravure and Flexo tick? Market shares Cost – The differentiating factor in an ever more cost-sensitive world. Outlook – What may change the game? Closing

Closing • • • • • •

Technical benefits of either Flexo or Gravure over one another may be identified, but can only be weighed in light of particular print jobs. The best achievable print qualities of either printing method are on a par, the average print quality level is typically higher with Gravure. Cost, versatility and „ever shortening-runlength“ aspects do speak for Flexo as the preferred method and the increased penetration of the digitally imaged fotopolymer sleeves is likely to enhance this trend. However, is the cost advantage of Flexo over Gravure still large enough to make an established Gravure printer invest in flexographic printing equipment? Maybe not. On the other hand, is the overall print quality benefit of Gravure over Flexo still large enough to make a Flexo printer invest in Gravure printing equipment? Again, maybe not. Therefore, we have something like an „impasse situation“ now.

Closing (continued) •

• • •

Admittedly, I am a Flexo proponent. In being so, I certainly don´t need to apologize for anything Flexo wouldn´t be capable of doing (quality, flexibility etc.), particularly in light of the further advancements that Flexo is about to enjoy. Nonetheless, I am far from declaring victory! When considering the overall level, Gravure is certainly the quality leader. We have experienced a time of “struggle” between the Flexo and Gravure printing methods in packaging printing. Instead, I am advertising a „peaceful co-existence“ of both the major packaging printing methods, Flexo and Gravure, for the purpose of advancing packaging printing as such. Please join me in this effort!

The Last Word

The Future comes step by step. That´s what makes it endurable. Alfred Polgar

ERA – European Rotogravure Association Packaging Conference 11-12 October 2006, Osnabrück, Germany

Flexo vs. Gravure in Packaging Printing Thank you very much!

Dr. Martin Dreher – DFTA-TZ, Stuttgart [email protected]