Rotogravure Printed Pouches | Printed Pouches & Rotogravure Printing
Rotogravure printed pouches are pouches that are printed via a intaglio printing process. This Gravure printing process is a complex one and involves meticulously laser engraving images directly into copper cylinders, which are then inserted into a commercial rotogravure printing machine. Once in the machine, these custom cylinders then add ink directly to printed pouches. The ink color being laid down by each must be calibrated or "registered" to ensure the best print outcome.
Roto presses can accommodate up to eight to ten colors and, since each cylinder is custom to your project it's a better option for higher-volume SKUs (5,000+), and scaling customers with repeat runs. Though a 5,000 MOQ may seem high, it used to be much higher -- advances in technology have brought down the MOQ. Yes, the lead times are longer and the MOQ is higher, but, for one, the color matching properties and per-unit cost of rotogravure printed pouches simply can't be beat. Rotogravure is a good one for scaling businesses, who want to take advantages of reduced unit cost as they order more bags.
GET A QUOTE ➡Key Features of Rotogravure
There are a few benefits that are specific to rotogravure printing, including a low cost per unit. Above we mentioned that the initial costs are higher than other methods of printing, but for large volume or repeat orders the overall cost per unit ends up being lower. With roto printing, the colors are both more accurate and more vibrant. We can match any (Pantone) color of the rainbow! Roto printing is high definition, with high DPI counts, and uses solventless inks for a truly high-quality end product.
| Advantages of Gravure Printing in Packaging | Benefits |
|---|---|
| Cost Efficiency | Low Cost Per Unit for large volume orders |
| Color Accuracy | Perfect Pantone Color matching capabilities |
| Print Quality | High Definition Roto Printing with superior DPI |
| Product Excellence | Premium Quality End Product with solventless inks |
SF POUCH’s Rotogravure Printing Process for Pouches
If SF POUCH is one thing, it’s consistent! This is why our rotogravure printing process is similar to our printing process for all our other bags. Here’s a look at what our rotogravure printing customers can expect when they partner with SF POUCH for their printing needs:
The Rotogravure Process
Pre-Press
Our pre-press team will help make sure your design is set up for optimal printing.
Color Separation
After final art approval your design is converted to color separations and engraved on the copper cylinders.
Printing
The design is printed onto the outermost layer of the pouch film.
Lamination
Once printing is complete, the film is laminated.
Final Product
After the laminated film is cured the pouches are made.
Digital Printing vs Rotogravure Printing
Rotogravure printing is preferred for its color matching properties and low cost per-unit benefits. The low CPU does come with a caveat though -- there's generally a 5,000 MOQ. If you're looking for a commercial print job and have lots to print, rotogravure is the best choice for you. The more you print, the cheaper the price per piece becomes. With rotogravure printing, you'll also have access to special custom inks, a larger variety of material structure types and custom finishes, and the highest possible printing quality. Simply put, roto printing = greater attention to detail and color vibrancy.
Of course, digital printing does have its uses, which we explain in-depth on our digital printing page. With digital printing, there are no printing plates costs and you can print only the amount you need (low MOQs!). Ultimately, digital printing is the more accessible option.
Digital Printed Pouches
Digital printing is the process of printing digital-based images directly onto your package. Artwork is separated into five ink colors: white, cyan, magenta, yellow and black (CMYK+W) This type of printing is best for small runs, or where you have a lot of different designs. Some advanced coatings, and techniques (Spot UV, Spot Matte) are not possible with digital printing.
Pros
- No setup costs but higher per unit costs
- Great for start-ups and seasonal SKUS
- Shorter lead-times, get your bags faster
- Great at printing raster images and photos
- Perfect for short runs, some as low as 200 zipper pouches
- Physical proof available
- Can be used with most material
Cons
- Higher bag costs
- Not advisable for higher quantities
- Limited finish options and printing effects
- Unable to exact color match PMS colors and some other limitations
Rotogravure Printed Pouches
Plate printing is commercial printing where the design of your bag is separated into multiple color plates. Plate printing yields the lowest per unit costs available. Brands you see in Walmart, Target, and so forth generally use plate printing. Most jobs can be completed with three to six plates. Use of metallic color may require additional plates. Use up to 10 colors.
Pros
- Lowest per-unit cost than digital printing
- Great for scaling businesses and larger orders
- All Finish options are available
- Works with the widest selection of materials
- Full range of print effects, metalized, holographic, etc
- True PMS ink colors can be used
- Exceptional print durability and better ink opaqueness
Cons
- Minimum order quantity 5,000 or more pouches
- One-Time Plate costs of $150 per color
- Not advised if you plan to make large design changes often
- Physical proofing not practical
Shrink materials and plastic films for rotogravure printing
For our rotogravure printing projects, we don’t actually print individual bags. Instead, we print rolls of material that’s laminated and converted separately into bags. Although any base material can be digitally custom printed, here are some of the most common materials and plastic film sheets we use for our rotogravure projects:
Metalized PET films
This is our line of metalized PET films, and is an economical and effective option for pouches. Metalized PET films is free from toxins, including BPA, TSE and sulfur, and Phthalates.
Clear barrier films
Clear barrier films are the backbone of barrier packaging. Our clear base barriers are affordable and provide protection against moisture and oxygen.
Aluminum barrier films
Like clear barrier films, foil barrier packaging materials offer an incredible barrier to oxygen and water. Our Aluminum foil barrier films material gives you the barrier of aluminum with the added strength of mylar.
