21 Jun Rotogravure myths
- What is rotogravure printing?
- How does rotogravure work?
- Rotogravure applications
- Advantages of rotogravure
- Rotogravure myths
What is rotogravure printing?
Nowadays there are many options and techniques for printing. Depending on the type of run or quality sought, one technique or another is chosen: digital printing, rotogravure, offset, flexography or screen printing.
Rotogravure –also known as intaglio or niello– is a technique that is used for direct printing. It works through chalcography, i.e. by tracing the ink applied on a product so that it is reflected on another. This is bas-relief printing, which means that the ink is applied in holes or cells and is then transferred to the material. In rotogravure printing, the deeper the cells in the bas-relief, the darker the areas that are printed, while a lighter tonality results from shallower cells.
How does rotogravure work?
The rotogravure printing process does not use printing plates, instead the graphic information is engraved directly on a metal cylinder. Metal cylinders transfer print directly to the material to be printed.
Rotogravure works as follows. The cylinders of the rotary system collect and transmit the ink which is printed directly on the support or material using pressure. This material passes sequentially from one cylinder to another in the form of a chain, in this way receiving the color and design of each one of them. The cylinders can be made of copper or bronze. They are engraved using diamond, one of the hardest materials in the world.
Four main elements come into play in this technique: the cylinder with small holes or cells, a doctor blade, a printing cylinder and the ink container. The cylinder rotates in the ink container whereby the cells on it are filled with ink. At the same time, the printing cylinder rotates. The doctor blade is responsible for collecting and removing excess ink. The material that passes through both cylinders is printed quickly.
Rotogravure applications
Rotogravure applications are widespread in different sectors:
- Press, such as newspapers or magazines
- Printing of packaging, decorative papers or wrappers
- Paper money printing
- Label printing
Advantages of rotogravure
- Photographic print quality
- High line screen, which increases the detail
- Color consistency, thanks to a simple color transfer mechanism
- High printing speed
- Low maintenance
- Fast ink drying
Rotogravure myths
Let’s have a look at the myths that exist about rotogravure and how Rieusset has found a way to challenge them.
It is only for long runs. Historically, it has been said that rotogravure is a system designed for long runs, large productions where a robust system is needed which is capable of maintaining constant quality – two arguments that are valid, but that are not linked to the need to be exclusively for huge print runs.
At Rieusset we have been able to dismantle this myth through two planned and differentiated actions. Taking as a base a company recognized for its quality and service, 5 years ago we began to construct a printing ecosystem that would maintain the advantages of rotogravure without the condition of exclusivity for long runs. We invested in two facilities that today make this possible:
- A fully automated cylinder engraving line, which allows optimization of engraving costs, with the advantage of being totally independent, offering a fully integrated service from start to finish.
- Acquisition of a medium-web (650mm) rotogravure line optimized for runs of between 10,000 and 20,000 m2.
Delivery times are long. Speaking in terms of short and long delivery times is a language that Rieusset does not use on a day-to-day basis. For us, a long delivery time is one that is not met, and therefore we see it as a problem.
At Rieusset we work with standard and optimized delivery times for clients. The standard terms are equivalent to those offered in the market, 3 weeks for repeat orders and 4 weeks for new ones.
The additional week for new orders is not linked to the printing system, but to our company’s commitment to ensure that the material delivered meets the level of quality desired by the client, which allows us to do things right the first time.
Our cylinder engraving process is a 100% robotized line with high productivity, since we can engrave cylinders 24 hours a day, 7 days a week. We have more than 7,000 cylinders, which allows us to react effectively on time.
Via certain indicators, our company continuously measures the level of efficiency at three levels: quality, delivery time and quantity. In all three indicators we maintain success rates above 99%.
It is not flexible. It is indeed paradoxical that the belief that the rotogravure system is not flexible has spread; for us flexibility is one of the pillars that defines us as a company.
We are aware of our position between suppliers and clients, and for this reason, with the history that precedes us, we have learned to procure raw materials and auxiliary materials efficiently, developing a process planning and optimization system that provides us with sufficient tools to respond in the time necessary for our clients, be it days or even hours.
It is very expensive. This is an easy statement to make, especially when only comparing any price per unit produced, leaving aside all the tangible or intangible benefits that we offer at our level of quality and service produced for our clients.
The constancy in the printing quality, the delivery service on time and in the quantity that we offer, the flexibility and reaction capacity that we are recognized for, and above all our predisposition to listen and understand the needs of our clients, are differential factors that have been valued throughout our more than 150 years of history.
If we quantify these factors, we can affirm that our price is fair and balanced, and that the increase in supply efficiency justifies the investment involved in working with us.
The decision to buy cheap can often be a rash one, since a company must earn money to do its job well in a sustainable way, adding value for its customers.
If you are not happy with the printing service that you are currently being offered and want to experience the advantages of rotogravure developed by Rieusset, we will help you improve your current situation, accompanying you and advising you to find the best solution for your needs.
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