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Rotogravure

Rotogravure, also known as gravure printing, is an intaglio printing process that utilizes a rotating cylinder engraved with recessed cells to hold and transfer fluid ink onto substrates such as paper, plastic films, or foils, enabling high-speed production of detailed images and colors.^[1]^[2] Developed in the late 19th century, rotogravure originated from photogravure techniques pioneered by Karel Klíč, who patented a method using copper cylinders in 1879 for reproducing artwork with superior tonal gradation and color depth.^[1]^[2] By the early 20th century, it evolved for commercial applications, with the first newspaper rotogravure section appearing in the Freiburger Zeitung in 1910 and the New York Times in 1912, leading to widespread adoption in pictorial supplements by the end of World War I, where 47 U.S. newspapers featured such sections.^[1] The process begins with etching or engraving microscopic cells into a copper-plated steel cylinder using electromechanical or chemical methods, where cell depth and shape determine ink volume for tonal variations.^[2]^[3] Ink, typically low-viscosity and solvent-based, fills these cells on the rotating cylinder; a doctor blade scrapes away excess ink from the surface, leaving ink only in the recesses.^[3]^[4] The substrate is then pressed against the cylinder by an impression roller, transferring the ink image, which is dried—often with hot air—before passing to subsequent color stations in multi-unit presses that typically handle four colors (cyan, magenta, yellow, and black).^[2]^[3] Rotogravure excels in long production runs due to its durability, with cylinders capable of printing millions of impressions without degradation, and it produces consistent, high-quality results with rich colors, smooth gradients, and fine details that resist smearing.^[2] These attributes make it ideal for applications including flexible packaging (such as food wrappers and labels on materials like BOPP or PET films), magazine and catalog printing, wallpaper, and security features like currency backgrounds, though it is less economical for short runs due to high setup costs for cylinder preparation.^[2]^[4]^[3] Despite its advantages, rotogravure's reliance on solvent-based inks has raised environmental concerns, as publication gravure contributed an estimated 63,000 tons of volatile organic compound (VOC) emissions annually in the U.S. in 1977, accounting for about 15% of the total from the graphic arts industry—prompting ongoing research into water-based alternatives.^[3] Today, it remains a cornerstone of high-volume industrial printing, particularly in packaging, which constitutes the largest sector of gravure applications.^[3]^[2]

History

Origins and Invention

Rotogravure, a rotary variant of the intaglio printing process known as photogravure, was invented by Karel Klíč, a Bohemian painter and engraver working in Vienna, during the 1890s. Klíč, born in 1841, had earlier refined photogravure techniques in 1878 by improving etching methods for deeper tones and finer detail on copper plates. By around 1890, he adapted this to a rotary system using etched copper cylinders, creating the foundational principles of modern rotogravure for continuous, high-volume image reproduction. Rather than patenting the process, Klíč kept it as a trade secret to maintain competitive advantage, leading to the establishment of the first commercial rotogravure firm in 1895 with English printer Samuel Fawcett in Lancaster.^[5]^[6] This invention represented a pivotal transition from traditional flatbed photogravure, which relied on hand-etched or photographically exposed flat plates printed via slow, labor-intensive flatbed presses, to a rotary method employing seamless cylinders. The cylindrical approach allowed for etching images directly onto curved copper surfaces that could be mounted on rotary presses, facilitating web-fed printing at much higher speeds while preserving the rich tonal range and detail of intaglio. The first operational rotogravure press appeared in 1893, marking the shift toward industrialized production capable of handling long runs of illustrated content.^[7]^[1] The emergence of rotogravure occurred amid the post-Industrial Revolution surge in demand for affordable, high-quality mass-produced illustrated magazines and newspapers, as advancements in papermaking and press technology enabled widespread visual journalism. In the United States, the process was introduced in 1903 and quickly adopted for pictorial supplements in publications.^[5]^[1]

Development and Key Milestones

Building on his earlier photogravure innovations from the 1890s, the technology had been introduced in the United States in 1903, setting the stage for broader adoption. The first use in a newspaper occurred in 1910 with a rotogravure section in the Freiburger Zeitung.^[1]^[5] Commercial breakthrough occurred in the 1920s, as publishers increasingly adopted rotogravure for its superior halftone reproduction and color capabilities in magazines and newspaper supplements. For instance, the New York Times launched its first complete rotogravure section on December 15, 1912, but widespread use accelerated by 1922 with Sunday magazine supplements becoming a standard feature in major newspapers, enabling mass distribution of high-quality photographic content.^[8]^[5] Publishers of fashion and lifestyle magazines capitalized on the process's ability to handle fine details in images.^[9] In the 1930s, automation improvements transformed rotogravure efficiency, with advancements in electromechanical engraving replacing labor-intensive manual methods and enabling precise cylinder preparation for multi-color printing. Companies contributed to these developments, leading to applications in packaging, such as the 1933 installation of a single-color gravure press for Tootsie Roll wrappers and 1938 multi-color presses producing 36,000 Jell-O boxes per hour.^[8]^[10] Following World War II, rotogravure expanded significantly in Europe and the United States, particularly in the 1950s boom for flexible packaging in the food industry, where its durability for long runs supported the growing demand for branded consumer goods.^[8]^[11] By the 1970s, rotogravure's use in newspapers declined due to competition from cost-effective offset lithography, which offered shorter setup times and versatility for varying run lengths, leading many publications to phase out gravure supplements.^[12] However, the process experienced growth in high-volume catalogs and labels, where its consistent quality and speed remained advantageous for large-scale production.^[9]

Printing Process

Cylinder Preparation and Engraving

The printing cylinder in rotogravure, also known as the gravure cylinder, serves as the image carrier and is typically constructed from a base of steel or aluminum sleeves that are electroplated with a layer of copper to provide a suitable surface for engraving.^[13] These sleeves are engineered for high precision, with common dimensions ranging from 1 to 4 meters in length to accommodate wide-format web printing and diameters of 10 to 20 centimeters to fit standard press configurations.^[14] The steel base offers structural rigidity, while aluminum variants provide lighter weight for easier handling in modern setups.^[15] In modern rotogravure printing, cylinder preparation primarily uses electromechanical engraving, where a diamond-tipped stylus, controlled by computer software, engraves cells directly into the copper surface based on digitized image data. This method allows precise control over cell size and depth to achieve tonal variations, with engraving speeds up to thousands of cells per second.^[13]^[2] Historically, chemical etching was used, involving the exposure of a light-sensitive carbon tissue—a gelatin-based material coated on a paper backing—to positives from film or digital files, hardening the gelatin in proportion to image density. The resist is then wrapped around the polished copper-plated cylinder, adhered with heat and pressure, and the backing peeled away to protect non-image areas during etching with ferric chloride solution in a series of baths.^[13] The core of the engraving process lies in the creation of recessed cells that function as ink wells, enabling tonal gradation through variations in cell size and depth.^[5] Highlight areas feature shallow and small cells to hold minimal ink for light tones, while shadow regions have deeper and larger cells to retain more ink for darker tones, achieving a continuous tone effect with cell walls typically 3 to 5 microns thick separating the cells.^[16] Cell depths generally range from 20 to 50 microns, directly influencing ink volume and print density.^[17] After engraving, the cylinder is electroplated with a thin chrome layer, approximately 0.01 millimeters thick, to enhance surface hardness and wear resistance during printing runs.^[18] Quality control during cylinder preparation involves meticulous inspection to verify cell integrity and performance, including microscopic examination or 3D scanning to assess cell volume, depth, and geometry for consistent ink-holding capacity and to minimize defects like uneven distribution.^[13]^[19] This step ensures consistent cell volume and distribution, minimizing defects that could affect print quality, such as uneven ink transfer or tonal inconsistencies.^[15]

Printing Operation and Ink Transfer

Rotogravure printing operates on a web-fed rotary press configured with multiple color stations, typically ranging from 8 to 16 units to accommodate up to 12 colors for high-volume production, enabling continuous operation at speeds of 300 to 1000 meters per minute.^[3]^[20] The press feeds a continuous web of substrate, such as paper or flexible film, through sequential printing units where each station applies a specific color layer, building the full image through precise overlays. This setup is particularly suited for long production runs exceeding 100,000 impressions, as the fixed engraved cylinders make short runs economically inefficient.^[21]^[22] During operation, the engraved cylinder rotates and dips into an ink pan filled with low-viscosity, solvent-based ink, allowing the microscopic cells on the cylinder surface—formed during pre-press engraving—to flood with ink. A doctor blade then wipes the cylinder surface under controlled pressure of 0.5 to 1.0 bar, removing excess ink and leaving reservoirs confined solely to the cells for sharp image definition.^[3]^[23] The substrate web passes between the printing cylinder and an impression roller, which applies light pressure (1–5 MPa) to facilitate ink transfer from the cells to the substrate via capillary action and surface tension, ensuring even deposition without smearing.^[20]^[21] Following transfer, the printed web immediately enters hot-air dryers operating at 120–180°C to evaporate the solvent carriers (comprising 75–80% of the ink), solidifying the image and preventing offset in subsequent stations.^[3]^[24] Color registration across stations is maintained through automatic side and length control systems, utilizing electronic sensors or pin mechanisms to align overlays within microns, compensating for web tension variations and ensuring vibrant, distortion-free multi-color results.^[21]^[25] This sequence repeats per color unit, with the web tension controlled throughout to sustain high-speed integrity and print quality.

Post-Printing and Finishing

Following the ink transfer in rotogravure printing, the printed web passes through an inline drying system to solidify the ink and prevent smearing or offset onto subsequent printing units. This process primarily employs hot-air dryers that circulate heated air—typically at temperatures between 120–180°C—to evaporate solvents from solvent-based inks, ensuring the ink film sets rapidly before the next color application.^[3]^[24] Alternatively, UV dryers may be used for specialized inks, curing the ink via ultraviolet light exposure in fractions of a second, though hot-air systems remain standard for most high-volume operations due to their compatibility with a wide range of substrates.^[21] The drying occurs interstation, with evaporation times typically ranging from 1 to 5 seconds per color unit, depending on line speed, ink volatility, and dryer configuration, allowing press speeds up to 1,000 meters per minute without compromising quality.^[26] Quality inspection follows drying to verify print integrity and consistency across the web. Automated vision systems scan the printed material in real-time, detecting defects such as hickeys (small ink spots), misregistration, streaks, or color deviations using high-resolution cameras and image-processing software.^[27] These systems often integrate with the press controls to halt production or adjust parameters if anomalies exceed thresholds, achieving defect detection rates above 99% in modern setups. Complementing visual checks, densitometers measure ink density on test patches to ensure color consistency, with tolerances typically held to ±0.03 density units, maintaining uniform reproduction throughout long runs.^[28] Basic finishing operations prepare the printed web for end-use, including inline varnishing to enhance gloss and protection, particularly in packaging applications where a lacquer coat is applied via an additional gravure unit. The web then undergoes slitting to divide wide rolls into narrower widths, followed by rewinding into finished rolls or sheeting for further processing. In roll-to-roll formats common for flexible packaging, the output remains as continuous reels ready for lamination or pouch-making; for magazine production, the web is cut into sheets post-printing for folding and binding.^[29]^[30] Waste management addresses cleanup between jobs to minimize downtime and environmental impact. Ink troughs and doctor blades are flushed with solvents or eco-friendly cleaners to remove residual inks, while cylinders undergo automated wash-up processes using ultrasonic or brush-based systems with specialized liquids that dissolve dried ink without damaging the chrome plating. These procedures recycle solvents where possible, reducing hazardous waste by up to 90% compared to manual methods, and typically take 5-10 minutes per cylinder.^[31]

Equipment and Components

Core Machinery

The core machinery of a rotogravure printing press consists of a robust, modular frame that supports multiple printing units arranged in a linear or stacked configuration, ensuring stability during high-speed operations. This frame typically incorporates drive shafts or electronic line shaft systems to synchronize the rotation of printing cylinders across units, utilizing either geared mechanisms for traditional setups or servo-driven controls for precise registration and reduced vibration. In modern presses as of 2025, shaftless designs using lightweight sleeves are increasingly adopted for rapid cylinder changes and reduced setup time.^[32]^[33]^[34] Key components include the ink fountain, equipped with recirculation pumps to maintain consistent ink supply and prevent settling, and the doctor blade assembly, which can be configured as oscillating for even wiping or fixed for simpler maintenance. The impression roller, covered in durable rubber to accommodate various substrates, applies controlled pressure to facilitate ink transfer from the cylinder to the web without excessive wear.^[35]^[36]^[37] Auxiliary systems enhance operational reliability, with automated tension controls regulating the web substrate's path to avoid wrinkles or breaks, and integrated cooling units circulating chilled water or air around the cylinders to sustain optimal operating temperatures, thereby minimizing thermal expansion and ensuring dimensional accuracy.^[38]^[39] Rotogravure presses are available in shafted designs, where cylinders are mounted on fixed shafts for enhanced rigidity in long runs, or shaftless variants using lightweight sleeves for rapid changes and reduced setup time, with print widths commonly spanning 1 to 3 meters to suit diverse applications from packaging to publication.^[34]^[40] Maintenance features often integrate cylinder storage racks for organized, protected holding to prevent damage from dust or impact, and in advanced setups, dedicated etching stations linked to the press line for on-site cylinder preparation and refurbishment.^[41]^[42]

Materials and Consumables

Rotogravure printing relies on specialized inks formulated for high-speed transfer from engraved cylinders to substrates. Solvent-based inks predominate, characterized by low viscosity to facilitate rapid filling and emptying of cylinder cells, typically achieved through binders such as nitrocellulose or polyurethane resins.^[43]^[44] These inks generally contain 15-25% solids by weight, with the balance consisting of solvents like alcohols or esters to ensure flow properties, and pigments added for color opacity and durability.^[44] Water-based alternatives, using acrylic or polyurethane emulsions, serve as eco-friendly options by minimizing volatile organic compound emissions, though they require adjustments for drying dynamics.^[45]^[46] Substrates in rotogravure must accommodate the process's high-speed, continuous web handling, favoring flexible materials with suitable mechanical and surface properties. Common choices include paper stocks weighing 60-120 grams per square meter (gsm), which provide adequate porosity for ink absorption without excessive penetration.^[47] Plastic films such as polyethylene terephthalate (PET), often in thicknesses of 10-50 micrometers, are widely used for packaging due to their tensile strength exceeding 50 MPa and resistance to tearing; polyethylene (PE) films, with lower tensile strength of 10-40 MPa, are used for less demanding applications.^[48] Foils like aluminum add barrier properties but demand primers for enhanced ink adhesion, measured via surface energy levels above 38 dynes per centimeter.^[49] Selection prioritizes substrates with balanced ink receptivity, ensuring uniform wetting and minimal defects during transfer. Key consumables support cylinder maintenance and ink metering in the printing workflow. Doctor blades, essential for wiping excess ink from the cylinder surface, are typically made of high-carbon steel for durability or polymer composites like polyurethane for reduced abrasion on chrome surfaces; lifespans vary depending on operating conditions, inks, and materials, with polymers often lasting longer than steel in abrasive environments.^[50]^[51] Etching chemicals, primarily ferric chloride solutions at 40-50° Bé density, dissolve copper to form cells during engraving, requiring precise concentration control to avoid over-etching.^[52] Chrome plating baths, using chromic acid electrolytes with sulfate catalysts, deposit a 0.005-0.01 mm protective layer on cylinders post-etching, enhancing wear resistance for runs exceeding 1 million impressions.^[53]^[54] Material compatibility ensures reliable performance across the process, with ink drying rates calibrated to substrate porosity to prevent smearing or incomplete set-off. Porous papers absorb solvents quickly via capillary action, necessitating faster-evaporating formulations, whereas non-porous films like PET rely on surface evaporation, often aided by heated air dryers. Viscosity is controlled at 15-25 seconds efflux time using a Zahn Cup #2, optimizing flow for cell flooding without excessive tailing during transfer.^[55] Cost considerations arise from high ink usage due to the flooding mechanism that fully charges cells, contrasting with lower consumption in non-flooded processes.^[56]

Applications

Traditional and Commercial Uses

Rotogravure played a pivotal role in magazine and catalog printing, delivering high-fidelity color reproductions that captured intricate details and vibrant hues. From the 1920s through the 1980s, it was widely adopted for Sunday supplements in major newspapers, such as the New York Times' inaugural full rotogravure section in 1912, which by the end of World War I appeared in 47 American publications and became the most read feature by 1932 according to George Gallup surveys. These sections often showcased fashion photography, high-society events, and artistic reproductions, leveraging the process's superior tonal gradation and color consistency. For retail catalogs, rotogravure enabled the mass production of large-circulation mail-order editions, exemplified by Sears, Roebuck and Co.'s annual catalogs, which featured colorful product illustrations on the same high-speed presses used for magazines.^[1]^[57]^[58] In the realm of commercial packaging, rotogravure excelled in producing flexible materials for food and tobacco products, including wrappers, pouches, and laminated films. Its intaglio method ensured sharp, scuff-resistant prints that maintained visual appeal over extended periods, making it ideal for items demanding durability and long shelf life, such as snack packaging and cigarette wraps. Coated papers optimized for rotogravure further enhanced print quality in food contact applications, while multi-layer structures protected tobacco goods during storage and distribution. This versatility positioned rotogravure as a standard for high-volume packaging lines, where consistent ink transfer onto substrates like polyethylene and paper was essential.^[59]^[60]^[61] For wallpaper and decorative home goods, rotogravure facilitated the creation of seamless, continuous patterns during the mid-20th century boom from the 1950s to 1970s, when bold floral and geometric designs proliferated in residential interiors. The process's engraved cylinders allowed for rapid, uniform reproduction on rolls of paper or vinyl, supporting mass-market production that aligned with postwar housing expansions. Its adoption in this sector stemmed from the need for economical yet detailed patterning, revolutionizing output compared to earlier hand-block methods.^[62]^[63] The precision of gravure printing techniques, from which rotogravure evolved, made them valuable for early security printing, particularly stamps and bonds starting in the 1910s. Nations like Germany employed photogravure for Bavarian postage stamps in 1914, followed by Mexico in 1917 and Britain for War Tax stamps in 1918, appreciating its ability to produce intricate, forgery-resistant details. Similarly, it contributed to banknote production through intaglio-derived techniques, ensuring high-resolution vignettes and security features on currency. This application highlighted rotogravure's role in safeguarding valuable documents with subtle tonal variations imperceptible to casual replication.^[64]^[65] By the mid-20th century, rotogravure dominated long-run color printing in sectors requiring runs of 75,000 to millions of copies, such as publications and packaging, due to its low unit costs and high-speed capabilities. The process's suitability for extended production runs without quality degradation further entrenched its commercial prominence.^[66]

Modern and Specialized Applications

In the 2020s, rotogravure printing maintains a dominant position in flexible packaging, accounting for a substantial portion of the global market valued at approximately USD 33.3 billion in 2024 and projected to grow to USD 40.6 billion by 2029 at a 4.0% CAGR, particularly for high-volume applications such as snack food wrappers and pharmaceutical blister packs that require high-barrier films for product protection and shelf-life extension.^[67] This process excels in producing vibrant, consistent prints on materials like polyethylene and polypropylene, enabling multilayer laminates that meet stringent regulatory standards for moisture and oxygen barriers in pharmaceuticals. It is also used for serialized secondary packaging to comply with regulations like the EU Falsified Medicines Directive (FMD), supporting anti-counterfeiting through unique identifiers.^[68]^[69] Rotogravure is widely employed for premium labels and tags, including high-end wine bottle labels where its ability to deliver intricate designs and metallic effects enhances brand aesthetics on pressure-sensitive or wet-glue substrates.^[70] It also supports RFID-integrated packaging by printing conductive inks and antennas onto flexible films, facilitating smart labeling for inventory tracking in supply chains.^[71] Specialized applications include decorative laminates for flooring and automotive interiors, where rotogravure prints wood-grain or textured patterns on overlay papers that are then impregnated and pressed into high-pressure laminates for durability and visual realism.^[72] In currency production, some countries utilize rotogravure for security features on polymer notes, applying specialized inks to create micro-text and holographic elements that enhance anti-counterfeiting measures.^[71] Emerging trends in the 2020s integrate hybrid gravure-digital systems for short-run e-commerce packaging, combining rotogravure's high-speed bulk printing with digital personalization to produce customized boxes and pouches efficiently for online retail demands.^[73] Additionally, rotogravure enables roll-to-roll printing of photovoltaic films, depositing thin layers of organic or perovskite materials onto flexible substrates to fabricate large-scale solar cells with power conversion efficiencies up to 16.7% in pilot productions (as reported in 2020).^[74] Globally, over 37,000 rotogravure presses operate worldwide, with the majority concentrated in Asia—particularly China and India—driven by export-oriented flexible packaging industries serving food, consumer goods, and electronics sectors.^[75]

Advantages and Disadvantages

Key Benefits

Rotogravure printing excels in superior color consistency due to its direct ink transfer mechanism from engraved cells to the substrate, which minimizes variations in hue and density over extended production runs. This process achieves stable color reproduction, ensuring uniform quality even in high-volume operations.^[57] The technology supports high-speed production, with modern machines capable of operating at speeds up to 450 meters per minute, making it particularly efficient for print volumes exceeding 500,000 units. This rapid throughput is optimized for long-run applications, as detailed in the printing operation and ink transfer processes.^[38] Fine detail reproduction is a hallmark of rotogravure, enabled by precise cell gradation on the cylinders that allows screen rulings of 150-300 lines per inch (lpi), facilitating exceptional resolution for photorealistic images and subtle vignettes.^[76] Printed products from rotogravure demonstrate notable durability, with inks that resist fading and abrasion, rendering them suitable for demanding applications like outdoor packaging.^[77] The process offers versatility in handling a wide range of substrates, from flexible films and foils to papers, without the plate wear concerns common in other printing methods, thanks to the robust, long-lasting engraved cylinders.^[57]

Limitations and Challenges

Rotogravure printing involves significant high initial costs, primarily due to the custom engraving of cylinders required for each job, which can range from $1,700 to $2,300 per color depending on complexity and size.^[78] For a multi-color job, these expenses can accumulate to $5,000–20,000 or more, making the process uneconomical for short print runs of fewer than 50,000 impressions where the per-unit cost remains prohibitive compared to alternative methods.^[79]^[80] The setup time for rotogravure operations is another major hurdle, typically requiring 8–24 hours for cylinder etching, chromium plating, and precise mounting on the press, which limits production flexibility and increases turnaround times for new jobs.^[81]^[79] This extended preparation phase demands careful coordination and can lead to bottlenecks in high-variety printing environments. Ink waste poses an operational challenge in rotogravure, as the engraved cells retain some excess ink even after doctor blading, leading to higher material consumption and disposal costs per run.^[82] This inefficiency is exacerbated by the use of solvent-based inks, which contribute to volatile organic compound emissions during evaporation.^[83] Technical limitations include difficulties in reproducing fine text below 8-point size, where ink from adjacent cells can spread due to the discrete nature of engravings, resulting in blurred or illegible details.^[84] Additionally, the process is highly sensitive to substrate tension variations, with small fluctuations causing stretching, misalignment, or defects in the printed image.^[85]^[86] Rotogravure demands skilled operators for optimal performance, particularly in adjusting doctor blade angles and pressures to minimize streaking or uneven ink transfer, as improper settings can lead to frequent downtime and quality inconsistencies.^[87]^[88] Training in troubleshooting cylinder wear and tension controls is essential, as these tasks require precision to maintain consistent output across long runs.^[89]

Technological Advancements

Innovations in Engraving and Automation

The transition to electromechanical engraving in rotogravure printing marked a significant evolution during the 1980s and 2000s, replacing traditional chemical etching with diamond stylus-based systems like the Helio-Klischograph developed by HELL Gravure Systems.^[90] Introduced in the early 1960s but widely adopted in subsequent decades, this method uses a vibrating diamond tip to directly engrave cells into copper-plated cylinders, enabling etch-free production that significantly reduces chemical usage compared to acid-based processes.^[91] By eliminating the need for ferric chloride etching baths, electromechanical systems minimize environmental hazards and waste disposal requirements.^[92] Post-2010 digital advancements have further transformed engraving through direct laser technologies, allowing for precise, contactless ablation of cylinder surfaces to create high-resolution cells.^[91] Systems like the Laser Ablation Mask System (LAMS) and UV-sensitive photoresist imaging enable variable data printing, such as personalized packaging elements, by facilitating rapid adjustments without physical retooling.^[91] These innovations support shorter setup times—often reduced to hours rather than days—through faster imaging speeds and lower energy demands.^[93] Hybrid approaches, integrating computer-to-plate (CTP) workflows with electromechanical elements, such as Ohio's hybrid engraving combining vibration and line techniques, produce sharp-edged cells and continuous-tone images in a single pass, enhancing versatility for complex designs.^[91] Automation in rotogravure presses has advanced with servo drive systems, which provide independent motor control for precise synchronization across units, achieving register accuracy below 0.1 mm even at high speeds.^[94] These drives enable real-time adjustments to tension and speed, reducing misalignment in multi-color printing.^[95] In the 2020s, AI integration has introduced defect detection and predictive maintenance, as seen in BOBST's smartGRAVURE system, which employs AI-driven data analytics via BOBST Connect to predict maintenance needs and detect print defects in real-time, minimizing downtime in gravure operations.^[96] Lightweight aluminum cylinder sleeves have streamlined press operations by allowing quick swaps without full cylinder disassembly, typically reducing changeover times to around 30 minutes.^[97] These sleeves, often weighing under 4 kg, fit over mandrels for easy installation and removal, supporting efficient job transitions in high-volume environments.^[98] These engraving and automation innovations have seen widespread adoption in new rotogravure presses, enabling economically viable shorter runs while maintaining quality.^[99]

Environmental and Sustainability Aspects

Rotogravure printing has historically relied on solvent-based inks, leading to significant volatile organic compound (VOC) emissions that contribute to air pollution and smog formation. Traditional processes can emit VOCs at levels requiring regulatory oversight, with the European Union's VOC Directive (1999/13/EC) establishing limits on solvent inputs for activities like rotogravure to reduce emissions, complemented by the REACH regulation since 2007 for safer chemical management in inks and solvents. In the United States, the Environmental Protection Agency's standards for publication rotogravure limit organic hazardous air pollutants to 8% of total volatile matter used monthly, promoting the use of low-VOC materials or capture systems to mitigate environmental release.^[100] Waste generation in rotogravure includes etching sludge from cylinder preparation and ink residues, which pose disposal challenges due to heavy metals and solvents. However, advancements in closed-loop systems have enabled higher recycling rates for solvents and inks, with some facilities achieving near-total recovery of printing forme materials to minimize landfill use. The process's inherent reusability of base cylinders supports a high overall recycling potential, aligning with circular economy principles by reducing raw material consumption across production cycles.^[101]^[102] Efforts to enhance sustainability have focused on green innovations, such as the adoption of water-based inks in rotogravure since the mid-2010s, which can reduce VOC emissions by up to 80% compared to traditional solvent-based formulations by minimizing evaporative losses during drying. UV-curable inks further support environmental goals by enabling rapid curing with lower heat requirements, achieving energy savings of up to 70% over conventional thermal drying methods through LED UV technology that generates less waste heat and eliminates solvent evaporation. These ink types, while referencing broader material developments, integrate into rotogravure to lower operational emissions without compromising print quality.^[103]^[104] The carbon footprint of rotogravure is influenced by high energy demands in drying, typically ranging from 2-5 kWh/m² in roll-to-roll operations due to hot-air systems evaporating solvents.^[105] Despite this, lifecycle assessments indicate variations in environmental impact depending on the printing method and scale; for example, flexographic printing can achieve up to 50% reductions in greenhouse gas emissions compared to rotogravure in certain high-volume packaging applications.^[106] Emerging trends as of 2025 emphasize bio-based solvents derived from renewable resources to further cut fossil fuel dependency, driven by stringent regulations like California's Air Resources Board (CARB) standards on VOC controls for industrial printing.^[107]

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Gravure Printing - an overview | ScienceDirect Topics
Gravure printing uses an engraved plate or roller to transfer ink from carved cavities to a substrate, often using a doctor blade to remove excess ink.
[22]
Rotogravure printing process - BOBST
The rotogravure process is a direct transfer method for printing onto wood-pulp fiber based, synthetic, or laminated substrates.
[23]
Rotogravure - DG press
Due to the high cylinder engraving and production costs, Rotogravure is economically unattractive for print jobs with a short- or medium-run length. Health ...
[24]
[PDF] Gravure settings
Use a blade pressure of 0,5-1,0 bar, increase more if there is no clean wipe, but try to use as low blade pressure as possible. (Less blade flex and blade/ ...
[25]
Solvent ink drying hot air system - M M Thermal Engineering
Consistent air temperature (usually 120–180°C) is critical to avoid smudging, colour bleeding, or improper adhesion. Energy Efficiency Instead of using boilers ...
[26]
Introduction To The Rotogravure Printing Process - Oyang Group
Aug 31, 2024 · Rotogravure involves coating a plate with ink, removing excess, and using a cylinder to transfer ink to a substrate via a doctor blade and ...
[27]
Method for improving drying speed in printing process and fast dry ...
... drying printing ink. Line speeds of 609 to 945 meters per minute are typically employed in a conventional rotogravure printing process. [0005]. The rotogravure ...
[28]
Print inspection systems for rotogravure machines - ATE Enterprises
High quality print inspection systems for rotogravure printing machines. Our vision inspection systems are proven to reduce costs and boost productivity.
[29]
Densitometric Color and Image Analysis - Offset Print Quality Control
Oct 25, 2013 · The densitometer is used to provide numerical feedback on ink film thickness. These optical density readings are taken from solid color patches ...
[30]
ROTOGRAVURE PRINTING - ServoArtpack
By printing on front/reverse at the same time, we are able to apply various finishes, enabling additional effects on the shelf, like matt varnishes, tactile ink ...<|control11|><|separator|>
[31]
Slitting and Rewinding - Printgraph
Slitting and Rewinding. We offer Rotogravure Printing Presses with Electronic Line Shaft (ELS) Drive that offer faster set up time during changeover of jobs, ...
[32]
Multiple cylinder cleaning - Flexo Wash
The Multi Cylinder Cleaner cleans up to 400 rotogravure cylinders per day with a modular concept specialized multi cylinder cleaning for your needs.Missing: waste management
[33]
Shaft Driven Rotogravure Printing Press Dpm - Packaging Labelling
The shaft driven rotogravure printing press DPM is an economical, basic model with shaft driven registration, a rigid frame, and a rigid doctor blade.
[34]
Rotogravure Printing Press With electronic line shaft technology
The press features Electronic Line Shaft Technology (ELS), better operator access, reduced noise, faster print register, integrated register control, and high ...
[35]
How Does a Rotogravure Printing Machine Work? - HSING WEI
Main Components of a Rotogravure Printing Machine. Printing Cylinder: The core component engraved with grooves that hold and transfer the ink. Ink Fountain ...
[36]
Gravure printing machine parts and components
Sep 17, 2025 · The Printing Unit: Core of the Gravure Press · Engraved Cylinder: This is the most critical component. · Ink Fountain: This is the reservoir that ...
[37]
Rotogravure Printing Machines | FUJI KIKAI KOGYO Co.,Ltd.
Rotogravure printing is a high-precision method that supports a wide variety of product printing, such as food packaging films and wood grain patterns for ...Missing: output | Show results with:output
[38]
KTGP-ES450 Series Electronic Line Shaft Rotogravure Printing Press
This Electronic Line Shaft (ELS) High Speed Rotogravure Printing Machine is Suitable for Roll To Roll Printing Materials Such As BOPP, CPP, PET, PVC, PE, Nylon ...
[39]
Ink Temperature Control Systems: Reduce Solvent Evaporation and ...
Jul 1, 2025 · Learn how ink temperature control systems help reduce solvent loss, lower VOC emissions, and improve print quality in rotogravure and ...
[40]
MASTER RS 6003 - Gravure printing - Overview | BOBST
Available with either shafted or shaftless print cylinders and different levels of automation, this versatile platform handles a wide range of substrates, ink ...Missing: rotogravure | Show results with:rotogravure
[41]
Rotogravure Printing Machines - Electronic Line Shaft - Standard
Machine Type: Electronic Line Shaft - Standard; Model: Rotoflex – ELS STANDARD With Self Shaft Chucking (Shaftless); Max Web / Printing Width: Maximum – 1320 ...Missing: shafted | Show results with:shafted<|separator|>
[42]
Gravure Cylinder Lines - Heliograph Holding
Print shops with their own cylinder making operations can integrate all production areas – from fully automated cylinder storage racks to cylinder making lines, ...Missing: maintenance etching
[43]
Partner - KASPAR Graphic Solutions
Inline transportation and storage systems and input/output stations for automatic gravure cylinder production lines; Automatic gravure cylinder and flexo ...
[44]
Global Gravure Printing Inks Market Size, Share, Trends, and ...
Gravure printing inks are the surface printing inks with low viscosity and oil resistant properties. This type of ink is generally used for printing on ...Missing: rotogravure | Show results with:rotogravure
[45]
https://www.bobst.com/en/news/detail/article/1615188545-water-based-gravure-printing-working-together-for-a-sustainable-future/
[46]
Water-based gravure printing: working together for a sustainable future
Mar 8, 2021 · Water-based inks greatly reduce VOC emissions as these most often contain a maximum of 30% solvents in the formula. Not only does this reduction ...
[47]
What Type of Ink Is Used for Gravure Printing? - HSING WEI
Water-based gravure printing ink is an eco-friendlier alternative, containing fewer volatile organic compounds (VOCs). It is primarily used in food packaging ...<|separator|>
[48]
Processed materials - Gravure printing - BOBST
Paper may be between 0.07 mm and 0.18 mm thick, with paper for printing and packaging applications generally being in a range between 60 and 120 gsm. The ...Missing: 60-150 | Show results with:60-150
[49]
[PDF] TigerPrints - Clemson OPEN
Oriented 48 gauge (12.3 µm) PET films are common and maintain an excellent tensile strength. ... substrates and works well with plastic films, foils and papers.Missing: rotogravure | Show results with:rotogravure
[50]
Investigation on electrostatic assist and gravure process parameters ...
Aug 6, 2025 · The surface energy of the substrate determines the adhesion and wettability of ink, while electrical properties such as surface and volume ...
[51]
FAQ About Doctor Blade Suppliers and Flexo Printing - Allison Blades
There is no easy answer. Doctor blades can last anywhere from a few hours to several weeks, depending on the operating parameters of their specific application.Missing: rotogravure lasting
[52]
Doctor Blades - FlexoParts.com
Plastic & Composite Doctor Blades For Flexo, Coating, and Gravure applications. Composit and plastic blades are designed to offer cost-effective performance.Missing: rotogravure lasting
[53]
[PDF] Rotogravure Printing - Heimann Hamm
The small portable instrument is designed for the fast measuring of copper and chrome coating thickness of rotogravure cylinders. Measurements are effected ...
[54]
https://sterc.org/pdf/sf2002/sf02q02.pdf
[55]
[PDF] Chloride-Based & Chloride-Free Products For the Rotogravure ...
The key to the whole rotogravure process is the quality of the “cell” structure. The cell is engraved into the copper plated surface prior to chrome plating.
[56]
Understanding Water-Based Printing Ink Viscosity Standards
Nov 21, 2024 · Gravure Printing: Requires a lower viscosity, around 15-25 seconds (Zahn Cup #2), to ensure optimal transfer. Screen Printing: Higher ...Missing: rotogravure | Show results with:rotogravure
[57]
[PDF] Inking Methodology - PrintPlanet.com
ink is equal to 0.5-1.0g/m2. ▫ When printed with gravure, the amount of white ink is equal to 1.0-2.0g/m2. Where the film packaging has 100% colour ink.Missing: consumption m²
[58]
Publication Rotogravure Printing Background Information For ...
... catalogs are printed on the same rotogravure presses. Most of these items are in full color. The combination of these gravure products accounted for O over ...
[59]
Industry 2.0: The Printing Press - Significans Automation
The Sears catalogue, Playboy and National Geographic magazines were examples of rotogravure printing. Screen-printing or silk screening is not a new ...
[60]
Coated papers - Ahlstrom
Ahlstrom's coated flexible packaging papers are one-sided papers suitable for food, tobacco and hygiene packaging. They offer excellent print quality.
[61]
Wholesale Printing Tobacco Packaging Bags with Zipper
So Haide provides superior quality, flexible and cost effective tobacco packaging bags. We ensure that our tobacco bags are produced with supreme quality ...
[62]
Rotogravure Printing, Flexo Printing Operation, Flexible Packaging ...
2) Complete know how of solvent base and solvent less machines. Knows different structure of flexible packaging, paper packaging for food, tobacco, Cosmetics, ...
[63]
A Quick Glance at the History of Print - Roto-Graphic Printing, Inc.
Gravure printing originated during the Italian Renaissance in the 1300s when fine engravings and etchings were cut by hand into soft copper. Today, images are ...Missing: traditional examples
[64]
Wallpaper Printing Methods: Part II - Pattern Observer
Jun 2, 2014 · Gravure printing (sometimes referred to as rotogravure) developed in the 1950s and revolutionized printing. ... Initially developed in the mid ...Missing: 20th century
[65]
None
### Summary of Gravure Use in Stamp Printing (1910s and Early 20th Century)
[66]
[PDF] The Security Printing Practices of Banknotes - CORE
Intaglio printing is produced by plates on which images are recessed, much like gravure printing which is the commercial term for this type of printing.Missing: stamps 1910s<|separator|>
[67]
[PDF] IMPACT OF TECHNOLOGICAL UPGRADATION ON PRINTING ...
... century remained the commonest method until mid 20th Century. Before ... Rotogravure is used for long runs - 75000 to millions of copies at low cost ...
[68]
https://businesslandtrading.net/gravure-printing-on-blister-foil/
[69]
Gravure Printing on Blister Foil - Business Land Trading
Gravure printing, also known as rotogravure ... Gravure-printed blister foil is used extensively in pharmaceutical packaging for: Tablet and capsule blister packs.
[70]
Gravure printing packaging for wine - All4Labels
All4Labels is a digital printing pioneer with more than 20 years of experience. We are specialists in packaging for wine, our experience allows us to create ...
[71]
Security Inks - SICPA
Our security inks are developed for all levels of authentication and a wide range of printing processes including intaglio, offset, silkscreen, gravure, ...
[72]
Gravure Printing Cylinder: The Manufacturing Process, Application ...
Decorative Printing: Gravure printing cylinders are ideal in the production of decorative laminates, wallpapers, flooring materials, and upholstery fabrics.Missing: rotogravure | Show results with:rotogravure
[73]
Digital hybrid packaging with metallic gravure - All4Labels
The offset technology enhancing the finishing with UV coatings, silk-screen printing, drop-off effects, hot foil, and micro-incisions for a unique look. digital ...We Are Expert In Special... · How Can We Help You With... · Engineering TechniquesMissing: e- 2020s
[74]
Roll-to-roll gravure-printed flexible perovskite solar cells using eco ...
Oct 13, 2020 · Herein, we demonstrate R2R-processed flexible PSCs at pilot scale through gravure printing, antisolvent bathing and subsequent annealing process ...Missing: rotogravure | Show results with:rotogravure
[75]
Gravure Printing Inks Market Share & Trends [2033]
Oct 13, 2025 · More than 37,000 gravure printing presses are currently operational worldwide ... Asia-Pacific led demand, with China and India ...
[76]
Rotogravure printing machine - All industrial manufacturers
In addition to extremely stable printing at the 18,000 sheets per hour maximum printing speed, ...
[77]
[PDF] Rotogravure Printed UHF RFID Antennae Directly on Packaging ...
In this work, rotogravure ... traditional rotogravure press set-up. Various ... and performing antennae than 300 lpi, while maintaining good print quality.<|control11|><|separator|>
[78]
[PDF] Printed Dot Quality in Response to Doctor Blade Angle in Gravure ...
Dec 2, 2017 · Its advantages include high print quality, high- speed production and hardwearing image cylinders which allows duplicating in millions. [8] ...
[79]
https://infomachinery.com/gravure-printing-machine-buying-guide/
[80]
Gravure Printing Machines 2025 | Complete Buying Guide
✓ Advantages of Gravure Printing · Exceptional Print Quality: High-resolution, photo-like images with sharp details. · Durability and Longevity: Engraved ...
[81]
Gravure Printing for Long Runs: Is It Always the Best Choice?
Feb 20, 2025 · Gravure printing is the best choice for extremely long runs, but it doesn't make sense for short-run printing due to high costs and long setup times.Missing: length | Show results with:length
[82]
Gravure Printing vs Flexo: In-Depth Analysis for Printers - KETE Group
Oct 8, 2024 · 200 – 400 m/min (~650 – 1300 ft/min) Fast and highly efficient for most applications. 300 – 600 m/min (~1000 – 2000 ft/min) Generally faster and ...
[83]
https://www.starcolor-ink.com/ink-knowledge/printing-technology-579.html
[84]
Can Gravure Printing Use Water-Based Inks?
Mar 12, 2025 · This efficiency comes at a cost: A single gravure press emits ~10 tons of VOCs annually, with 20–30% of ink expenses allocated to waste-gas ...
[85]
10 Things You Need to Know About Rotogravure Printing in Flexible ...
1) Can only be one color printing with strokes less than 0.4mm · 2) Printing lines should be no less than 0.2mm · 3) Be careful with shallow screen printing · 4) ...
[86]
Top 4 FAQs About Rotogravure Printing
Apr 30, 2025 · Substrate Tension Fluctuation: Traditional tension control allows fluctuations of ±5N, causing substrate stretching or shrinking. Upgrading ...
[87]
Effect of Tension on Conductivity of Gravure Printed Ag Layer in Roll ...
Aug 6, 2025 · The elongation of substrate generates cracks inside the printed layer. The formation of crack triggers increasing in electrical resistance and ...
[88]
ROTO 101 – Operator Best Practices (Series 2 of 4) | Doctor Blades
Feb 20, 2018 · ROTO 101. Operator Best Practices. Second in a 4 Part Series on Key Elements of the Rotogravure Process.
[89]
Gravure Press Operator Job Description, Duties, Skills & Career Path
Sep 11, 2022 · Adjust rotogravure press: Thread webs of paper or other printing stock through the press and further adjust temperature, guides, and tension ...
[90]
rotogravure printing press operator
Top 4 skills for rotogravure printing press operator. 1.Doctor blade a)Doctor blade hardness and flexible. Blade hardness will affect printing quality.
[91]
Gravure Printing
Rudolf Hell some 50 years ago heralded the era of etch-free industrial printing form manufacture using the HelioKlischograph – a prerequisite for today's fully ...
[92]
Gravure Imaging - Heliograph Holding
The launch of electromechanical engraving with HELL's HelioKlischograph some 50 years ago heralded the era of industrial manufacturing of gravure cylinders – a ...
[93]
(PDF) Automated Engraving of Gravure Cylinders - Academia.edu
The study reveals that using digital scanning and automated engraving significantly reduces the preparation time by eliminating 90% of conventional ...
[94]
(PDF) Laser Precision Micro Fabrication in the Printing Industry
Aug 8, 2025 · Direct laser engraving into the metallic surface is the fastest and most versatile process for gravure cylinder imaging (ablation rate up to 1 ...
[95]
DNAY800C Computerized Register Rotogravure Printing Machine
Rewinding traction tension: 0-25kg(Servo control); 11. Register precision: Vertical ±0.1mm. 12. Main motor: Servo motor 11KW; 13. Heating type: Electric ...
[96]
Machine Directional Register System Modeling for Shaft-Less Drive ...
They showed that the register fluctuation could be kept within ± 0.1 mm using the developed nonlinear register controller. ... ... In order to improve the control ...<|separator|>
[97]
Predictive maintenance successfully introduced in the newspaper ...
Apr 20, 2021 · Koenig & Bauer has successfully launched its predictive maintenance services for printing press owners in the newspaper and commercial web ...
[98]
BOBST is revolutionizing the gravure printing process with ...
May 22, 2024 · BOBST smartGRAVURE revolutionizes the traditional gravure printing process by adding innovative elements of automation and digitalization.Missing: AI defect detection KBA 2020s
[99]
Flexographic Printing: The Power of Print Sleeves & Bridge Sleeves
Apr 11, 2025 · “Bridge sleeves slash changeover times by up to 40%,” Morales says. “I've watched clients switch jobs in minutes, not hours, keeping pace with e ...Missing: rotogravure | Show results with:rotogravure
[100]
Rotogravure – Cylitec
May 12, 2022 · COPPER PLATED LIGHTWEIGHT CYLINDER · It weighs between 30% and 50% less than a conventional steel cylinder, depending on the size. Body made of ...Missing: length | Show results with:length
[101]
Rotogravure Printing Machine Market Share Analysis
Feb 22, 2025 · Discover key players' market share in rotogravure printing machines. Explore competition, trends, and growth potential.Missing: century | Show results with:century
[102]
40 CFR § 63.824 - Standards: Publication rotogravure printing.
Each publication rotogravure affected source shall limit emissions of organic HAP to no more than eight percent of the total volatile matter used each month.
[103]
[PDF] Strengths and ecological aspects of gravure printing
It is, however, generally true that almost no waste is generated in the gravure printing production cycle and the process has a very high recycling rate.
[104]
[PDF] Gravure Printing and Sustainability
Gravure printing offers great potential for the circular economy: its major ecological advantages are the reusability of the print forme (base cylinder) and ...
[105]
Gravure Printing Inks Market Size, Share, Trends & Forecast
Rating 4.6 (47) According to the U.S. Environmental Protection Agency, water-based inks can reduce VOC emissions by up to 80% compared to solvent-based alternatives. This ...Missing: rotogravure | Show results with:rotogravure
[106]
Three Advantages of UV LED Curing for Package Printing
Sep 12, 2024 · Some experts cite up to 70% energy savings compared to mercury. ... UV LED curing doesn't emit harmful chemicals or VOCs. This helps package ...Missing: rotogravure | Show results with:rotogravure
[107]
Analysis of Drying and Annealing Effects in R2R Processing
Drying and annealing stages are particularly energy-intensive, with conventional hot air systems consuming between 2-5 kWh/m² of processed material.
[108]
Life Cycle Assessment | DuPont Packaging Graphics
Results of a Life Cycle Assessment performed by DuPont show 50% savings in greenhouse gases for flexo vs. gravure printing.
[109]
(PDF) DLC-engineered flat gravure surface: enabling sustainable ...
Jul 9, 2024 · The study of DLC as gravure surface is important because it has durable surface. The DLC fabrication process does not produce toxic waste, while ...