Digital Printing

Rotogravure Printing

• Process: Digital printingapplies ink directly onto the substrate using electrophotographic printing technology. The artwork is printed from a digital file, without the need for physical cylinders /printing plates.

• Process: Rotogravure involves engraving the image onto a cylinder /printing plate, which is then used to transfer ink onto the substrate. This method is mechanical and requires a significant setup process.

• Flexibility: Highly flexible, ideal for short runs and quick changes to the design.

• Consistency: Known for its consistent high-quality prints, especially for long runs.

Digital Printing

Rotogravure Printing

• Quality: Offers excellent print quality with fine details and vibrant colours. However, it may not match the absolute precision of rotogravure for large, complex designs.

• Quality: Provides extremely high print quality, particularly for complex designs, fine details, and full coverage prints.

• Colour Consistency: May vary slightly between batches, but advanced colour management can minimise these differences.

• Colour Consistency: Superior colour consistency over long runs, making it ideal for large-scale productions with minimal variation.

Digital Printing

Rotogravure Printing

• Setup Costs: Low setup costs as no physical cylinder/printing plates are required, making it cost-effective for short runs and prototypes.

• Setup Costs: High initial setup costs due to the creation of engraving cylinder/printing plates, making it more expensive for short runs.

• Per Unit Cost: Generally higher per unit cost compared to rotogravure, especially as quantities increase.

• Per Unit Cost: Lower per unit cost for large volumes with MOQ of 10,000, making it more economical for long runs.

Digital Printing

Rotogravure Printing

• Turnaround Time: Fast, with minimal setup time, allowing for quicker production and shorter lead times.

• Turnaround Time: Longer lead times due to the complex setup process, including cylinder/printing plate engraving and press setup.

• Adjustments: Easy to make changes or updates to the design without significant downtime.

• Adjustments: Difficult and costly to make changes once the cylinder/printing plates are engraved.

Digital Printing

Rotogravure Printing

• Best For: Short to medium runs, personalisation, and multiple SKUs with varying designs.

• Best For: Long runs where the cost of cylinder/printing plate engraving can be amortised over large quantities.

• Versatility: Ideal for companies that need frequent updates to their packaging or want to test new designs.

• Efficiency: More efficient for large-scale, high-volume production with the same design.

Digital Printing

Rotogravure Printing

• Customisation: Highly customisable with the ability to print variable data, such as personalised names, unique designs, or limited editions on each pouch.

• Customisation: Less flexible for customisation due to the fixed nature of engraved cylinders/printing plates.

• Design Flexibility: Allows for quick design changes and multiple versions in a single print run.

• Design Changes: Changes require new cylinders/printing plates, making it less practical for frequent updates or multiple variations.

Digital Printing

Rotogravure Printing

• Waste: Typically generates less waste since no cylinder/printing plates or excessive materials are needed. Less ink wastage due to precise application.

• Waste: Produces more waste, particularly in the setup and printing phase.

• Energy Use: Generally lower energy consumption compared to rotogravure.

• Energy Use: Higher energy use due to the extensive setup process and mechanical operation.

Digital Printing

Rotogravure Printing

Use Cases: Ideal for food and non-food packaging with frequent design changes, limited editions, seasonal promotions, or when quick turnaround is needed.

Use Cases: Best for mass production of packaging with consistent branding, such as food and beverage packaging, where high volumes and quality are paramount.

Market Fit: Suitable for small to medium-sized companies or brands with diverse product lines.

Market Fit: Ideal for medium to large scale companies with high-volume consistent demands.

Rotogravure Printing

Digital Printing is best for shorter runs, quick turnarounds, and projects requiring high customization. It’s cost-effective for smaller quantities and flexible in design changes.

Rotogravure Printing excels in long runs with consistent high-quality prints. It’s more cost-effective for large volumes but comes with higher setup costs and longer lead times.

Digital Printing

Rotogravure Printing

Minimum order quantity

1,000

10,000

Lead Time

Shorter than rotogravure for quick turnaround, no set up required

Greater than digital due to cylinder design set up

Set up costs

No

Yes for cylinder(s)/print plate(s)

Packaging size

Maximum size limitations

Large size options available

Finishes

Limited finishes available

Various finishes available

Unit cost

High for small productions

Low for large productions

Ideal for

Low quantities, multiple low quantity SKU’s, short runs, last minute orders or start-up businesses testing products.

High volume, large scale productions, reproductions, large scale planned orders or established businesses with huge demand.