Printed Flexible Packaging Suppliers

Print process comparison: rotogravure, flexo, and digital

The three primary print processes for flexible packaging each offer different trade-offs between print quality, setup cost, run length economics, and lead time. Rotogravure printing uses engraved metal cylinders — each colour requires a separate cylinder that is laser-engraved to the artwork. Gravure delivers the highest print quality for flexible packaging: exceptional colour consistency across very long runs, fine detail reproduction (including fine text and photographic imagery), smooth tonal gradients, and metallic or special-effect inks. Cylinder engraving cost is typically $800–2,500 per colour; a 7-colour design may require $6,000–18,000 in tooling before any material is printed. This setup cost makes gravure economical only at run lengths of 50,000+ units. For food brand owners and FMCG buyers printing large volumes of branded flexible packaging, gravure is the standard. Flexographic printing uses photopolymer plates at significantly lower setup cost than gravure. Print quality has improved substantially and modern flexographic printing approaches gravure quality for most applications. Plate cost is typically $200–800 per colour. Suitable for medium runs (5,000–50,000 units), less complex designs, and packaging that does not require photographic-quality colour reproduction. Digital printing for flexible packaging uses inkjet technology — no plates or cylinders, so setup cost approaches zero. Enables short runs (from 500 units), quick turnaround (days rather than weeks), and variable data or versioning. Colour gamut and ink adhesion have limitations compared to gravure for some applications. Increasingly used for sampling, niche SKUs, promotional runs, and personalised packaging.