How to Use Rotogravure Printing to Achieve High-quality Coffee Packaging

In modern marketing, packaging serves not only as a protective layer for products but also as a direct means of communication with consumers. While the design artwork is important, choosing the right printing method is equally crucial, as it directly impacts the visual appeal of the packaging.

After all, the first thing consumers see when considering a purchase is the coffee bag, and that initial impression can significantly influence their decision.

Therefore, a reliable printing method must align with brand requirements, ensuring that images and text effectively highlight brand design, while utilizing sustainable packaging materials and adhering to a reasonable budget.

High-quality coffee packaging not only shapes brand identity but also provides customers with extensive information about the coffee itself. However, among the various printing methods available, which one yields the best results?

Although the rotogravure printing process is a primary method for producing large quantities of high-quality printed materials, its high initial setup costs and complex plate-making process make it less common, leading to longer product delivery times.

In this article, we will delve into the process and applications of rotogravure printing, comparing it with other printing methods to assist brands in making informed choices regarding coffee packaging.

What is rotogravure printing?

Rotogravure printing, commonly known as rotogravure, involves engraving an image onto a specific carrier surface chosen based on surface finish and barrier performance requirements. This technique ensures that the carrier surface meets the desired specifications for both appearance and functionality.

Modern gravure printing machines utilize laser-engraved printing cylinders, with minute cells specifically designed to hold ink, their dimensions and arrangement precisely corresponding to the intended image.

As a popular printing method with a history of over a century, rotogravure printing is favored by manufacturers for its ability to transfer more ink onto materials.

Although gravure printing requires an initial investment for each color, resulting in higher costs, we will store and maintain the plates on your behalf.

We can ensure that no new plates need to be created when you return an order, thereby guaranteeing color consistency across each batch of packaging.

In the coffee packaging industry, it is essential to carefully select the most suitable printing process.To attract consumers, both the images and text must be clear and stand out on the shelves.

While flexographic and digital printing are widely used, research indicates that rotogravure printing is particularly favored for its quick turnaround, low cost, and high reproduction quality.

How Does Rotogravure Printing Work?

The rotogravure printing process begins with etching or engraving a design onto the surface of a printing plate. Ink is then applied to the plate, and excess ink is wiped away. When the film substrate comes into contact with the inked plate, the ink transfers to the substrate.

Each color requires a separate engraved plate, with the engraving depth adjusted to achieve the desired color intensity.  Deeper cells produce more vibrant colors than shallower ones. Both CMYK and Pantone colors can be used in the printing process.

Rotogravure cylinders are typically made of steel and coated with copper, although ceramic materials can also be employed. A doctor blade is used to remove any excess ink from areas not meant for printing, making precise engraving depth important for the process. This blade ensures that only the intended patterns are transferred to the substrate.

Additionally, the impression cylinder is essential for moving the printed object to the next color in the sequence, ensuring a smooth and efficient printing operation.

Why Choose Rotogravure Printing

Gravure printingt has many advantages as below for you to consider and choose it for your coffee packaging solution.

High Quality

The use of engraved cylinders ensures impressive color density, capturing everything from the faintest shades to the richest dark tones. Precise, solid and vivid.

High-Speed

Gravure printing operates at remarkable speeds, achieving production rates of up to 10-15 meters of film per second. The use of fast-drying solvent-based inks in gravure printing also significantly accelerates the overall printing process.

Color and Printing Consistency

This direct printing technique ensures superior ink application and maintains a consistent quality throughout the print.

Money Cost-efficiency

Due to its high level of automation, gravure printing incurs relatively low labor costs, and the durability of gravure cylinders allows for multiple print runs with proper maintenance.

Is Rotogravure Printing Sustainable?

Experts agree that rotogravure printing is among the most sustainable methods available, thanks to the durability of its printing cylinders.

A single cylinder can produce over 20 million impressions, minimizing the raw materials needed for plate production.

Additionally, rotogravure consumes less energy per square meter than other methods, reducing carbon emissions over time.

Recyclability of inks is also important. Many roasters seek sustainable packaging materials like kraft paper or PLA, but if inks can’t be removed, recycling is difficult.

At Gozen Packaging, we use sustainable water-based inks with low VOC content, suitable for compostable substrates. These inks decompose completely without releasing harmful toxins into the environment.

Tell Your Story with Custom Rotogravure Printing

Gozen Packaging is thrilled to provide a variety of eco-friendly flexible packaging solutions tailored to meet each brand’s unique needs.

Our offerings include fully recyclable mono-material PE bags, biodegradable options like PLA and corn starch, and a range of printing surfaces, from glossy and matte to soft touch and spot UV effects.

Each choice is designed to enhance both the visual appeal and environmental sustainability of your products.

If you’re uncertain about the best printing solution for your bakery or have any questions, feel free to contact our sales manager at info@gozenpackaging.com. We’re here to assist you in finding the perfect packaging solution!