At Gualapack, we pride ourselves on utilizing state-of-the-art printing technologies to meet the diverse needs of our customers. With high-performance-laminate production plants in Italy, Ukraine, Romania, Mexico and Brazil, our facilities employ Rotogravure, Flexographic, and Digital printing to deliver high-quality, efficient, and sustainable solutions.
Each of these printing methods has distinct advantages depending on the type of packaging material, the required print quality, and production volume. Understanding the strengths of each technology helps customers make the best choice for their specific needs. Below, we explore the key differences and applications of each technology within Gualapack’s global network, along with their benefits for our customers.
Rotogravure printing: premium quality for high volumes
Rotogravure printing, commonly known as roto printing, is a high-quality printing method that involves engraving the image onto a cylinder. This process ensures exceptional precision, vibrant colors, and durability, making it ideal for large-scale packaging production.
Rotogravure cylinders are typically made of steel with a copper surface, which is then electroplated with chrome. The steel core provides strength and durability, while the copper layer allows for precise engraving of the design. The chrome plating enhances wear resistance, ensuring longevity and consistent high-quality printing over long production runs. This structure ensures excellent image reproduction and durability.
Advantages:
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Superior print quality with high-resolution images
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Consistent and durable prints, even for complex designs
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Excellent colour reproduction and opacity, up to 10 colours
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Efficient for long production runs due to minimal setup costs per unit
Customer benefits:
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Brand consistency: ensures that packaging maintains a premium look and feel across multiple batches.
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Cost efficiency for large runs: once the cylinders are created, high-volume printing becomes highly economical.
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Durability for transport and shelf life: the high-quality finish ensures that the packaging remains intact and visually appealing throughout the supply chain.
Gualapack’s use of rotogravure:
At Gualapack, we implement reverse printing on the inside of the laminate when using rotogravure printing. This ensures that the ink does not come into contact with the inner packaging, maximizing food safety and preventing any alteration of the print quality due to abrasion.
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In the laminate production plants in Italy, Romania and Ukraine Gualapack employs rotogravure printing for laminated packaging solutions, ensuring premium quality.
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Gualapack Brasil integrates rotogravure with flexo printing in its production processes, providing high-definition printed packaging to the local market.
Flexographic printing: versatile and cost-effective
Flexographic printing, or flexo-printing, uses flexible rubber or photopolymer plates that are mounted onto rotating cylinders. These plates transfer ink onto the substrate with high speed and precision. The flexibility of the plates allows them to conform to different surface textures, making them ideal for printing on various materials, including films, paper, and corrugated boards. The use of anilox rollers ensures consistent ink distribution, enhancing print quality and reducing ink waste.
This process is known for its ability to print on a wide range of substrates, making it a popular choice for both flexible and rigid packaging applications.
Advantages:
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Faster setup times compared to rotogravure
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Cost-effective for medium to large production runs
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Suitable for printing on diverse materials, including plastics and paper
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Up to 10 colours
Customer Benefits:
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Affordability for medium-sized runs: offers a cost-effective solution without compromising on quality.
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Quick turnaround: faster setup and printing speeds allow for more efficient order fulfillment.
Gualapack’s use of flexographic printing:
Similar to our rotogravure process, Gualapack employs also reverse printing on laminated materials when using flexographic printing. This technique ensures that the ink remains protected inside the layers of the packaging, providing an added layer of food safety while maintaining pristine print quality.
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In Mexico, Excel Nobleza employs flexoprinting technologies, optimizing efficiency and quality for different packaging needs.
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Gualapack Brasil uses flexographic printing as well as rotogravure printing offering a broad range for high-quality packaging.
Digital printing: innovation for short runs and customization
Digital printing is a technology that transfers images directly onto the packaging material without the need for printing plates. This method allows for high flexibility, customization, and rapid production, making it ideal for small batch sizes, variable data printing, and personalized packaging solutions.
Advantages:
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No need for printing plates, reducing setup time and cost
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High flexibility for small runs and customized designs
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Suitable for variable data printing (e.g., barcodes, QR codes, personalization)
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Minimal waste and reduced environmental impact
Customer benefits:
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Highly customizable: perfect for limited-edition packaging, seasonal products, and promotional campaigns.
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Quick market response: ideal for fast-changing market demands and product updates.
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Minimal waste: reduces material wastage, making it an eco-conscious choice for brands.
Gualapack’s use of digital printing:
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Gualapack Pharma specializes in digital printing for aluminum and PVC foils used in pharmaceutical blister packaging. This ensures precision and adaptability for the specific requirements of the pharma industry.
Choosing the right printing technology for your needs
Each of these printing technologies has its own strengths, and the choice depends on factors such as production volume, material type, and design complexity.
How Gualapack supports its customers:
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Consultative approach: we work closely with customers to determine the best printing solution for their specific needs.
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High-Quality standards: our advanced technology ensures that packaging meets regulatory and brand requirements.
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Global reach with local expertise: with facilities in multiple regions, we offer tailored solutions with regional market knowledge.
At Gualapack, we leverage our extensive expertise and global reach to offer tailored solutions that meet the highest industry standards. Whether our customers require premium laminated packaging, cost-effective flexible solutions, or highly customized digital prints, we have the right technology to deliver outstanding results.
For more information about our printing capabilities and how we can support your packaging needs, contact us today!
