Introduction

As environmental consciousness continues to rise, more companies and brands are embracing eco-friendly bags like laminated non-woven bags, laminated PP woven bags, and laminated RPET bags. However, the choice of printing method in the manufacturing process can significantly impact the quality and cost of the final product.

This article presents a comprehensive comparison between two widely used printing methods: gravure printing and digital printing, to help businesses make informed decisions when it comes to producing high-quality bags/packaging.

Gravure Printing

Gravure printing involves etching or engraving an image onto a cylinder (usually made of iron) to create recessed cells or dots. These cells hold the ink, and the excess ink is scraped off the cylinder’s surface. During printing, the substrate is pressed against the cylinder, and the ink is transferred to the substrate from the recessed cells.

Advantages of Gravure Printing

  • 1. Cost-Effectiveness (Large Quantity): Although gravure printing involves a time-consuming and costly cost for making printing plates, it becomes more cost-effective for large production runs. The per-unit cost decreases with increased quantities.
  • 2. Suitable for Specialty Inks and Spot Colors: Gravure printing can accommodate spot colors, specialty inks, metallics, and varnishes, enabling unique visual effects and tactile finishes, enhancing the overall appeal of printed materials.
  • 3. Save Plates Costs for Repeated Order (within 1 year): Once the printing plates are produced, they can be utilized multiple times during the printing process for repeated order without incurring additional costs, provided that the design remains constant within 1 year.
  • 4. No Limitations on the Print Size: Gravure printing can be able to produce prints in various sizes without any restrictions.

Limitations of Gravure Printing

  • 1. Long Setup Time: Gravure printing needs to making printing plates (cylinders), which can be time-consuming and costly, especially for short print runs or frequent design changes.
  • 2. Not Cost-Effectiveness (Small Quantity): The high initial setup costs make gravure printing less economical for small print quantities, making it more suitable for long print runs.
  • 3. Limited Flexibility: Unlike digital printing, which allows on-the-fly modifications, gravure printing needs to make new printing plates when it comes to design changes.

Best Use Cases for Gravure Printing

  • 1. Manufacturing bags/package in large quantities with consistent high-quality printing.
  • 2. Printing involves spot colors and specialty inks.
Laminated bag with gravure printing
non woven bag with gravure printing

See examples of our Gravure Printing laminated bags here.

Digital Printing

Digital printing is a modern printing technique (inkjet or laser) that involves the direct transfer of digital files onto a substrate, such as bopp, paper, fabric, or other materials. It eliminates the need for traditional printing plates or cylinders used in other methods like offset or gravure printing.

Advantages of Digital Printing

  • 1. Cost-Effectiveness (Small Quantity): As there is no cost for making printing plates (cylinders), digital printing is cost-effective for small production runs of bags/packaging.
  • 2. Shorter Turnaround Time: Digital printing eliminates the need for making printing plates (cylinders), resulting in a more efficient printing process. It is ideal for quick production and short lead times.
  • 3. Flexibility: Designs can be changed at any time for free, making printing design more flexible.
  • 4. High-quality Output: With advancements in technology, digital printers can produce high-resolution prints with excellent color accuracy and detail.
  • 5. Reduced Waste: Digital printing offers minimal waste since there is no need for plate preparation or ink mixing.

Limitations of Digital Printing

  • 1. Restricted Color Options: Unlike gravure printing, which can achieve specialized colors like metallics and spot colors, digital printing relies on the CMYK color model, limiting color accuracy for specific shades.
  • 2. Size Considerations: Digital printing has certain size limitations based on the equipment used. Oversized designs may require alternative printing methods.

Best Use Cases for Digital Printing

  • 1. Limited-edition prints
  • 2. Short-run orders for promotional events, trade shows, or special occasions.
  • 3. Brands looking to test new designs or concepts before committing to a large production run.
PVC ice packs / Digital printing
Non-woven fabric coating / Digital printing

See examples of our Digital Printing laminated bags here.

Making the Right Choice

  • 1. Quantity and Budget: Gravure printing is ideal for larger print quantities, while digital printing suits smaller runs and businesses with budget constraints.
  • 2. Time Sensitivity: When time is a priority, digital printing’s quick turnaround makes it the preferred choice.

Conclusion

In today’s dynamic market, small and fragmented orders are becoming increasingly prevalent. As a result, businesses are seeking more flexible and cost-effective printing solutions to cater to these demands. This is where digital printing shines. Understanding the strengths and limitations of both printing methods empowers businesses to make informed decisions.