By Daniel Strickland., owner, DJS Packaging Solutions

In flexible packaging, digital printing technologies are making impressive strides. With their ability to handle short runs, offer quick turnarounds and provide variable data printing, digital presses are expanding the possibilities in certain market segments. However, gravure and flexographic printing continue to evolve and innovate, too, maintaining their crucial roles in the flexible packaging ecosystem. These proven methods are not just holding their ground; they’re still actively shaping the future of flexible packaging production.

One of the most exciting parts of working in the packaging industry is seeing the sheer pace of change first-hand. For even the most seasoned of packaging teams, it’s inspiring how quickly technology is moving.

In flexible packaging, in particular, digital printing technologies are making impressive strides. With their ability to handle short runs, offer quick turnarounds and provide variable data printing, digital presses are expanding the possibilities in certain market segments. In some instances, with the right equipment, the in-hand quality of digitally printed packaging almost is indistinguishable from tried and tested methods.

However, gravure and flexographic printing – long-established pillars of the industry – continue to evolve and innovate, too, maintaining their crucial roles in the flexible packaging ecosystem. Although it’s digital tech that’s grabbing the headlines, these proven methods are not just holding their ground; they’re still actively shaping the future of flexible packaging production.

Meeting the scale of demand

One of the most compelling strengths of gravure and flexo printing lies in their capacity to handle high-volume production runs. While digital printing excels in short to medium runs, and it’s clearly getting better at longer runs, the speed and efficiency of gravure and flexo become indispensable when dealing with the massive scale required by global brands.

In the right conditions, a single flexographic press can print up to 600 meters per minute, while gravure presses can reach speeds of up to 1,000 meters per minute. These speeds are crucial for meeting the demands of large-scale consumer goods producers, which require millions of packaging units to be produced quickly and consistently.

The European flexible packaging market alone is projected to reach $23.1 billion by 2027, growing at a CAGR of 3.8% from 2020 to 2027, according to Allied Market Research. Much of this growth will be driven by large-scale production, where gravure and flexo printing continue to dominate due to their proven efficiency and quality at scale.

Quality that speaks volumes

There’s a good reason these methods have endured: Gravure and flexo have long set the gold standard for print resolution and color consistency in flexible packaging. Gravure, in particular, remains a trusted choice for premium packaging that demands intricate designs and perfect color reproduction.

The ability to lay down a thicker ink film allows gravure to achieve deep, rich colors and fine details that are challenging to replicate with other methods but are essential for grabbing consumer attention in a split-second. This importance can’t be overstated, since according to a study by the Paper and Packaging Board, 72% of consumers agree that packaging design influences their purchasing decisions.

Sustainability: Adapting to new challenges

Gravure and flexo printing are playing a crucial role in the industry’s push toward sustainability and circularity. As the European Union’s Packaging and Packaging Waste Regulation (PPWR) sets ambitious targets for recyclability and recycled content, these established printing methods are proving highly adaptable to meeting these challenges.

For instance, water-based and solvent-free inks, which are seen as more sustainable and easier to de-ink during recycling, have seen significant advancements in gravure and flexo applications. These inks not only reduce hazardous VOC emissions but also improve the recyclability of flexible packaging – a critical factor as the global packaging industry works toward the PPWR’s goal of making all packaging recyclable or reusable by 2030.

Moreover, the precision of gravure and flexo printing allows for the use of thinner substrates without compromising print quality. This reduction in material usage aligns perfectly with the PPWR’s emphasis on packaging weight reduction and resource efficiency.

Embracing mono-materials

Likewise, the shift to mono-material structures in flexible packaging, driven by recyclability goals, has presented both challenges and opportunities for printing technologies. Gravure and flexo have shown remarkable adaptability in this arena, too. The superior ink adhesion and durability offered by these methods are particularly valuable when printing on new, more sustainable substrates. As brands transition away from traditional mixed-material designs that are hard to recycle to mono-material packaging alternatives, the ability of gravure and flexo to deliver high-quality prints on these materials becomes increasingly important.

As a working example at the group represented by the author’s company, the KoroRCY range is a mono-material flexible packaging solution designed for post-consumer recycling. The substrate benefits from the precision and quality of these established printing methods to achieve the high-end finish brands demand, while still meeting sustainability goals. This challenges the preconceived idea that sustainability means compromising on quality.

Continuous innovation driving efficiency

The advantages of today’s flexo and gravure technologies are not just in terms of sustainability or quality; they also can exert a wider impact on process efficiency, helping to cut wasted time and costs. For example, advances in sleeve technology for flexo printing have reduced set-up times and waste drastically, which is a valuable benefit for smaller production teams. Modern flexo presses now can achieve job changeovers in a matter of minutes, offering flexibility for shorter runs while maintaining the benefits of high-speed production for longer runs.

Similarly, gravure has seen advancements in cylinder engraving technologies, with laser-engraved cylinders offering further improved quality and consistency, reducing the risk of print imperfections and the waste associated with it.

Driving innovation in smart packaging

As we know, today’s packaging evolves far beyond just branding and protecting a product. It’s the key touchpoint, a direct line to the consumer and a brand owner’s shop window. Increasingly, brands are seeking to actively engage with shoppers, and gravure and flexo print techniques are well-positioned to support emerging trends, like smart packaging.

The ability of gravure and flexo to print conductive inks with high precision opens up possibilities for integrated circuits and sensors directly on packaging materials, as well as pin-sharp run-to-run precision for QR code technology. This capability, combined with high-speed production, could be key to making smart packaging economically viable on a large scale.

As we navigate the complexities of modern flexible packaging production, driven by consumer demands, brand owner requirements and legislative changes, it’s clear that there’s no one-size-fits-all solution to packaging printing and there probably never will be.

Digital printing will continue to grow and excel in areas where short runs and personalization are key, but we must be careful not to overlook flexo and gravure techniques as we look to the future. Against the dazzle of digital, there’s a risk these techniques could be seen as outdated in comparison, and that’s not the reality. The enduring strengths of gravure and flexo printing – their speed, quality, versatility and adaptability to new materials and sustainability requirements – ensure their continued importance.

Instead of putting too many eggs in any one basket, the future of flexible packaging printing lies in the intelligent integration of various printing methods to meet the diverse and ever-changing needs of brands and their consumers. In this future, digital printing will work alongside gravure and flexo – not instead of – to drive innovation, sustainability and efficiency across the packaging industry.

The message to brand owners and our packaging industry peers is that while digital flexible packaging technology rightly captures our imagination and attention, the true future of flexible packaging lies in harnessing the strengths of all printing methods. In this evolving market, gravure and flexo aren’t just keeping pace – they’re helping to set it. 

Daniel Strickland is the owner of DJS Packaging Solutions, LLC, and works with Korozo Group to support and represent the international sustainable flexible packaging manufacturer throughout the USA, Canada and Mexico. For more information: www.djssystems.com.