What is the difference between flexo and gravure printing？

If you’re sourcing printed packaging, you’ve likely heard the terms “flexo” and “gravure”—but what do they really mean?

Flexo printing uses flexible plates and is ideal for short runs, while gravure printing¹ uses engraved cylinders and suits large-volume, high-quality jobs.

A few years ago, a coffee client in Australia asked me, “Which printing method will give me the sharpest logo without pushing up the MOQ?” That led me to explore this question from both cost and quality perspectives.

What are the materials used in flexible bag packaging²?

When it comes to packaging, material choice is everything—from protection to print performance.

Flexible bag packaging uses layered films like PET, PE, BOPP, and sometimes aluminum for barrier protection and printability.

Typical material combinations

Flexible pouches are usually made from laminated films³. These materials serve different roles:

Dive deeper: print compatibility

The outer layer must have excellent ink adhesion⁴. Here's how it aligns with printing types:

• Flexo printing: Works well on BOPP, PE, and kraft paper.
• Gravure printing: Preferred for PET and metallic films due to ink precision and drying capability.

At IMIPAK, we carefully match materials to print methods. For example, for coffee bags, we often recommend PET/VMPET/PE for gravure, and Kraft/PE for flexo—balancing both appearance and performance.

What is printing in flexible packaging?

Printing is where branding, safety info, and customer appeal all come together.

Printing in flexible packaging refers to the application of ink on packaging films using flexo or gravure processes.

Flexo vs gravure in practice

Here’s how each method works:

Dive deeper: which to choose?

• Choose flexo if you need small runs, fast delivery, and eco-friendly water-based inks.
• Choose gravure for detailed logos, vibrant colors, and high-volume production.

Some of our buyers start with flexo for market testing⁵, then switch to gravure as their volume grows.

How to make flexible packaging?

The production of flexible packaging is a multi-step process that combines materials, printing, and shaping.

Flexible packaging is made by laminating films, printing them, then converting into pouches or rolls.

Key manufacturing steps

1. Film extrusion – raw plastic is formed into thin layers.
2. Printing – flexo or gravure applies the design onto the outer layer.
3. Lamination – films are bonded together for strength and barrier.
4. Slitting – large rolls are cut into smaller widths.
5. Bag making – pouches are formed and sealed with zipper, valve, or spout.

Dive deeper: factory quality control

At IMIPAK, our factory runs 10 high-speed machines⁶, and each roll passes QC tests for:

• Ink adhesion
• Heat seal strength
• Lamination bond
• Pinhole inspection

This ensures each bag not only looks good, but performs in storage and shipping.

What material is used for gravure printing¹?

To get the most out of gravure printing¹, materials must be smooth and ink-friendly.

Gravure printing works best on high-gloss, heat-resistant films like PET, BOPP, and nylon.

Why PET and BOPP?

These materials are dimensionally stable, which is crucial during the high-speed, heat-intensive gravure process. They also accept solvent-based inks⁷ well, which dry faster and stick better.

Dive deeper: matching film to ink

Gravure uses solvent-based inks⁷ that need precise film compatibility. Poor matches can lead to:

• Ink smudging
• Poor drying
• Faded colors

To avoid this, we at IMIPAK test ink adhesion⁴ before full production. We even provide free printed samples so our clients can check performance before committing.

Conclusion

Flexo is fast and affordable. Gravure is rich and refined. Your product—and your priorities—decide the best fit.