How to make gravure printing plate for packaging bags?

Gravure printing delivers unmatched quality for packaging—but how are the plates made?

Gravure printing plates¹ are precision-engraved cylinders, created by coating steel rollers with copper, then etching the design into the copper layer.

I remember when a first-time buyer asked me, “Why does gravure printing have such a high setup fee?” The answer lies in the plate-making process. It's not just about printing—it's about engineering consistency and detail at scale.

What type of printing is used for packaging?

Packaging isn’t just a wrapper—it’s branding. And every print method creates a different visual experience.

The most common types of printing for packaging are gravure, flexographic, and digital—each with distinct advantages.

Comparison of printing types²

Gravure stands out for its ability to handle:

• Fine lines and gradients
• Rich, deep blacks and metallics
• Long runs with no color drift

Dive deeper: where gravure fits best

If you’re launching a premium coffee line with 8-color artwork and metallic accents, gravure is ideal. We’ve used it for clients in Japan and Europe who demand consistency across large volumes and strict brand guidelines.

But for startups testing new SKUs, flexo or digital might be more practical due to the lower entry cost.

What is the process of printing gravure?

The gravure process is highly technical and involves both chemistry and engineering.

Gravure printing involves image separation, cylinder preparation, engraving, chroming, and high-speed printing³ on flexible films⁴.

Step-by-step cylinder creation

1. Artwork separation – Each color is separated into a grayscale layer.
2. Cylinder base prep – Steel roller is cleaned and plated with copper.
3. Engraving – Design is etched into the copper (mechanical or laser).
4. Chroming – Thin chrome coat applied for durability.
5. Polishing – Smoothens surface for better ink transfer.

Gravure printing process

• Each cylinder is loaded into the press.
• Ink fills engraved cells on the cylinder.
• A doctor blade scrapes off excess ink.
• The film (PET, BOPP, etc.) passes between the cylinder and impression roller.
• Ink is transferred and dried quickly by hot air.

Dive deeper: precision matters

• Cell depth: controls ink volume per color
• Line screen: defines how sharp the image appears
• Registration: must align perfectly across all colors

That’s why gravure takes time—but the result is flawless. It’s perfect for multi-layer laminated rolls and premium printed pouches.

What are the disadvantages of gravure printing?

Gravure delivers quality—but not without trade-offs.

The disadvantages of gravure include high initial cost, longer lead time⁵s, and less flexibility for short runs.

Key limitations

Dive deeper: how to overcome limitations

At IMIPAK, we guide clients through these challenges:

• We offer flexo printing for short runs and test launches.
• For gravure clients, we store cylinders for repeat orders to save cost.
• We help optimize artwork to reduce color separations and plate counts.

For long-term brand scaling, gravure’s upfront cost pays off through print quality, speed, and consistency across markets.

Conclusion

Gravure printing plates¹ take time and cost more—but deliver unmatched precision, making them ideal for premium packaging.