Gravure printing, compared to other printing methods, has significant disadvantages. This is also true for rotary film printing. The loss rate of a unit-type gravure printing machine ranges from 6% to 7%, while that of a satellite flexo printing machine is only 1% to 2%. The difference is quite shocking. Even when using the same unit-type rotary printing method, the longer paper path in gravure printing results in much higher losses than in flexo printing. When changing rolls, even though 2 to 3 paper paths are required, the gravure printing machine’s longer paper path leads to significantly greater waste. This doesn't even account for the fact that gravure printing has the highest printing pressure among all methods. As a result, the loss per color group at mechanical synchronization speed is the largest, causing significant misregistration issues. Additionally, ink distribution in gravure printing contributes to quality losses. The knife wire (or knife line) can only be temporarily addressed, not completely eliminated.
It's extremely difficult to eliminate faults caused by the inherent characteristics of gravure printing. To improve yield, gravure printing companies have tried their best. For example, some have widened the printing door width—up to 1600mm—to reduce side waste and increase yield. However, the wider the machine, the harder it becomes to control the registration across the entire width of the material, leading to larger registration errors during printing. Despite continuous equipment upgrades and staff training, yield improvements remain limited. With rising raw material costs today, this challenge is becoming an almost insurmountable obstacle for gravure printing operators.
The quality issues associated with gravure printing stem from its inherent process flaws. Unfortunately, many professionals haven’t fully recognized this. Large losses in the printing process are often wrongly attributed to frontline workers, blaming them for poor skills or lack of responsibility. When setting up the printing process, management departments rarely provide detailed guidelines, instead relying on the on-site capabilities of the lead gravure operator. These front-line workers, limited by their knowledge, often depend on outdated experience. As a result, the current awkward situation in gravure process control has emerged: leaders are unable to effectively manage from above, while workers are unsure how to proceed. In the flexible packaging industry, the finished product rate is generally below 90%, and in some companies, it's even lower. Since the quality issues in gravure printing are inevitable, the only way to truly solve them is to learn from other processes and improve or transform the gravure printing process itself.
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