Technology Overview
Flexo uses flexible photopolymer plates. Plates can be produced in-house in hours. Cost: €500–2,000 per job. HD Flexo plates at 175+ lpi deliver near-gravure quality.
Gravure uses engraved copper cylinders manufactured by specialists. Lead time: 2–4 weeks. Cost: €3,000–8,000 per cylinder. Superior for very fine vignettes and long runs.
Run Length Economics
Short runs (<100,000m): Flexo wins decisively — cylinder cost difference alone (€6,000–18,000 for gravure vs €1,500–4,000 for flexo) makes gravure uneconomical. Medium runs (100,000–1,000,000m): Flexo increasingly competitive, especially with gearless fast changeover. Long runs (>1M meters): Gravure cylinder amortizes, plate replacement frequency gives gravure cost edge.
Environmental Comparison
Flexo: water-based ink compatible (gravure requires solvent), lower VOC, no copper electroplating waste, lower energy for drying. As environmental regulations tighten, flexo's advantage grows.
