The Granola King wanted to understand the advantages of gravure printing before choosing the right printing method for two new batches of granola pouches. Rich colour and clear bilingual text were key priorities for the project. In this case study, Advantages Of Gravure Printing are explored through the client’s challenges, the Canadian packaging requirements, and the final results achieved for The Granola King. Discover how the right printing choice helped meet the project’s print quality goals. The Advantages of Gravure Printing are also considered through the project’s print quality, production volume, and requirements of packaging.
Client Background and Packaging Requirements
The client behind The Granola King, the two new flavours, and the requirements of pouch are introduced in this section. These details help explain the Advantages of Gravure Printing for the client’s planned production volume.
The Granola King Premium Granola Brand
The client was the owner of The Granola King, a small batch granola maker in North Vancouver. A new range of 750g whole grain granola, made with Canadian honey and no preservatives, was planned for retail shelves, about 50,000 pouches were expected each month, zip lock stand up pouches with a premium look were needed, and the best printing type was not known. In his words, “We want our pouches to look premium on every shelf.” The advantages of gravure printing were explored to assess print consistency, fine details, and colour quality for the new packaging range. Read on to see the requests.
Deep Violet Wine Red Pouch Colour Needs
Two colour samples were requested: a rich abc for Blueberry Orange and a deep def for Hazelnut Hemp, each with a matte finish, gold foil lines, a crown shield logo, and a shield shaped clear window. Moreover, mylar bags with a matte laminate were considered for freshness. The advantages of gravure printing were relevant to the desired colour consistency and detailed artwork across large production runs. Explore Custom Printed Stand Up Pouches for the same premium look. Move on to the next part.
Pouch Thickness and Structure Needs
A laminated structure of about 130 microns was selected, with a matte PET outer layer, a barrier layer, and a PE sealing layer, with a resealable zipper and tear notches added. The advantages of gravure printing were considered for crisp artwork, consistent colour reproduction, and detailed designs across large production runs, while puncture strength was also expected from the selected structure. Continue to see where problems appeared.
Printing Challenges Faced by the Client
The problems found in the first printing plan are explained here, from dull colour to soft small text. Understanding these challenges also explains why the Advantages of Gravure Printing were relevant to this project.
Digital Printing Results Were Disappointing
Digital printing had been suggested by an earlier printer, and the client said, “Digital is what I want, because everyone says it is cheaper.” However, when the demand and the finish of the client were reviewed, this choice was found to be completely unsuitable. The result of digital printing is good on a glossy finish, but on a matte finish it is not good at all. It was selected only because of the lower price, so the final result was not liked by the client. The total cost over twelve months had not been calculated, colour was seen as dull, and detail was seen as soft. Uneven ink transfer was also noticed on the matte film. The advantages of gravure printing were therefore reviewed as a possible solution for consistent colour depth and fine artwork across large production runs. Keep reading to see how small text was tested.
Sharp Text on Matte Colours
Fine details were lost on the tiny nutrition, ingredient, and barcode text in two languages on the yellow back panel, and ink coverage was seen as patchy on the deep violet wine red backgrounds. The advantages of gravure printing, including precise detail reproduction and consistent ink coverage, were considered for these packaging requirements. Move on to see how colour was handled.
Colour Depth for Gold Foil Artwork
Precise colour matching was requested for the crown logo and the yellow back panel, and the wider colour gamut of the artwork was reviewed. Similarly, spot colours and metallic effects were discussed for the gold lines. The advantages of gravure printing were also evaluated for repeatable colour reproduction across large production volumes. Next, the final choice is explained.
The problems found in the first printing plan are explained here, from dull colour to soft small text. The following sections also highlight the key lessons from this project and explore Gravure Printing Problems And Solutions to help readers understand common printing issues and how they are addressed.
Why Was Gravure Printing Recommended?
How the samples were compared and why gravure was recommended for the pouches is explained in this section. The Advantages of Gravure Printing were assessed against the client’s colour, detail, and volume requirements.
Gravure vs Digital Printing Comparison
Samples of rotogravure printing and digital printing were prepared side by side. Colour depth and detail were stronger on the gravure sample, as shown below.
| Factor | Digital Sample | Gravure Sample |
| Small text on matte colours | Edges were soft | Clean and readable |
| Cost per pouch at high volume | Higher | Lower |
Side by side samples are prepared by Universal Packaging for your own artwork on request. Continue reading for the technical reason.
Digital Printing Suited for Banners and Posters
Digital printing is suited to banners, posters, sheets, sample runs, and short runs on glossy finishes, whereas flexible packaging with a matte finish is better served by another method. Learn why in the next section.
Gravure Suited for Pouch Films
For packaging printing on plastic films, gravure was recommended. The gravure printing process was explained in simple steps, the advantages of gravure printing were listed clearly, and a clear answer to why use gravure printing was given. Continue to the full list below.
Key Advantages of Gravure Printing
The main advantages of gravure printing are summarized below:
- Detail: logo and tiny text are reproduced sharply.
- Colour: every pouch is matched to the approved proof.
- Strength: ink is bonded firmly to the film.
- Durability: cylinders are trusted for long and high-speed runs.
- Compatibility: PET, BOPP, PE and CPP films are printed.
- Protection: artwork is protected through reverse printing and lamination.
- Presentation: complex artwork is reproduced with smooth gradients.
- Cost: the cost per pouch is lowered at high volumes.
- Eco choices: low VOC and water based inks are used.
Next, each point is explained in turn.
1. High Resolution Print Quality
Artwork was reproduced with high resolution printing, so fine image reproduction was achieved even on small text. Also, CMYK printing was combined with extra colours. The advantages of gravure printing are most visible here. Next, colour stability is discussed.
2. Consistent Colour Across Both Flavours
Colour consistency was kept from the first pouch to the last, in deep violet wine red. Consistent print quality was maintained over long print runs. Trust at scale is built through the advantages of gravure printing. Continue to see how inks were bonded.
3. Strong Ink Adhesion on Films
Inks were bonded firmly to PET film, BOPP film, and PE film, while aluminium foil layers were also printed, and laminated packaging was used so that print durability was increased. Abrasion resistance and scuff resistance were confirmed on the matte surface. Read on for cylinders.
4. Durable Cylinders for High-Speed Production and Bulk Orders
Engraved printing cylinders are used, and copper plated cylinders are trusted for large orders because a long life is expected from them. With cylinder engraving technology, even gradients are reproduced precisely. Likewise, high speed printing is supported once cylinders are approved. Discover Gusseted Mylar Bags for bulk orders with the same artwork.
5. Compatibility With Flexible Packaging Films
Gravure printing is used on flexible packaging materials including PET, BOPP, PE and CPP films. These materials are used as part of the multilayer structures that are made to manufacture pouches and bags. Because the same films are laminated in layers, the printed artwork is matched to the barrier and sealing needs of the pouch. A smooth film surface is also preferred, since an even layer of ink is received by it.
6. Protection of Printed Artwork Through Reverse Printing and Lamination
In reverse printing, the artwork is printed on the inner side of the transparent film, and the print is then sealed under a laminated layer. As a result, the print is protected from scratches, moisture, and handling, and abrasion is reduced on the matte surface. The ink is kept between the layers, so a longer life is given to the artwork on the shelf.
7. Better Presentation of Complex Packaging Artwork
Complex artwork such as the crown shield logo, gold lines, gradients, and two-language text is reproduced with smooth transitions and clean edges. Because the window shape and the artwork are registered carefully, the presentation of the product is improved on the shelf. These print quality results demonstrate another of the Advantages of Gravure Printing for detailed packaging artwork. See Shaped Bags for a future range with a unique outline.
8. Cost Efficiency at High Volumes
The cost per pouch was calculated at 50,000 pouches per month and was lower for gravure. This is why gravure printing applications such as FMCG packaging, snack packaging, coffee packaging, and pet food packaging are so common. In the same way, food packaging is prepared for food contact packaging rules. Next, greener choices are covered.
Benefits of Eco Friendly Inks for Pouch Printing
Greener ink choices, their benefits, and recycling goals are covered here.
Low VOC Ink Options
Eco friendly inks were selected for The Granola King pouches, and water based inks were discussed. Fewer volatile organic compounds (VOCs) are released when low VOC inks are used, so air quality in the plant is protected and the odour on the finished pouch is reduced. The benefits are listed below:
- Cleaner air: emissions are lowered during printing and drying.
- Lower odour: a fresher pouch is received by the customer.
- Food safety: ink choices are matched to food contact packaging rules.
- Brand trust: the reputation of the brand is strengthened through greener choices.
Browse Flexible Pouch Printing for wider choices in colour and finish. Keep reading for the packaging goals.
Sustainable Packaging for Granola Brands
Recyclable packaging was reviewed, and recycling compatibility was checked for each layer. Monomaterial packaging and post consumer recycled content were considered, and packaging waste reduction was set as a goal. Therefore, greener plans are supported through the advantages of gravure printing. Next, Canadian rules are explained.
Canadian Food Pouch Rules and Standards
Labelling, closure, and legal rules for food pouches in Canada are explained here, so the advantages of gravure printing are applied within them. Food packaging in Canada is governed by packaging regulations such as section B.23.001 of the Food and Drug Regulations (C.R.C., c. 870), made under the Food and Drugs Act (R.S.C. 1985, c. F-27), and the Safe Food for Canadians Regulations (SOR/2018-108) are also followed. Bilingual English and French labelling is required under section B.01.012, and the nutrition facts table is governed by section B.01.401, while the Made in Canada claim is guided by the Competition Bureau of Canada. Here, sharp small text is protected through gravure, so the advantages of gravure printing are valuable. View Smell Proof Bags With Lock for freshness control and a secure closure. Read on for the final production steps.
Sample Production Process
The sample was produced in stages. First, the artwork was set up with the deep violet wine red backgrounds, the gold lines, and the crown shield logo, and a digital proof was shared with the client. Then the cylinders were engraved, and a sample run was printed on the matte film and laminated. When the sample was reviewed, the depth of colour and the sharp bilingual text were praised by the client. Only small changes were requested: the thickness of the gold lines was adjusted slightly, and the yellow of the back panel was fine-tuned. After these changes were made, the final sample was approved.
Proof Approval and Repeat Orders
A digital proof was approved, cylinders were engraved, and brand graphics then stood out on both pouches, while shelf appeal was clearly raised. The visibility of the product was improved, and the advantages of gravure printing were noticed in every colour. A repeat order was placed by the client, and reorders were delivered within 15 days. The decision was called the best step taken for the brand. Explore a BOPET Packaging Bag for the next project. Read on for the lessons.
Conclusion
In this blog, we covered the whole journey, from the client request to the final pouch. The challenge, the printing comparison, the technical choices, and the Canadian rules were explained. Sharp detail, steady colour, and strong adhesion were achieved, and lessons for choosing between gravure and digital printing were shared. Looking for pouches printed with sharp detail and steady colour? At Universal Packaging, printing options are matched to your artwork, order volume, and budget. Rich colour and sharp bilingual text are now seen on the Granola King pouches. The advantages of gravure printing are best seen in real projects like this one, and the next packaging plan is best started with the right printing choice. Ready to start your project?
Frequently Asked Questions (FAQs)
What are the main advantages of gravure printing?
Sharp detail, steady colour, and strong ink adhesion are the main advantages. These gravure printing benefits for packaging are especially valued for pouches and films.
Is gravure suitable for small orders?
Gravure is best suited to larger orders, because the cost of engraving the cylinders is spread across a high number of pouches. For small or trial orders, the cost per pouch is higher, so the advantages of gravure printing are strongest in larger orders.
Which films are printed by gravure?
PET (polyester), BOPP and CPP (polypropylene), and PE (polyethylene) films are printed by gravure. Aluminium foil layers are also printed, so the advantages of gravure printing are seen on both clear and metallized structures.
4. Which Canadian rules apply to granola pouches?
Granola pouches are governed by the Food and Drugs Act (R.S.C. 1985, c. F-27) and the Food and Drug Regulations (C.R.C., c. 870), and the Safe Food for Canadians Regulations (SOR/2018-108) are also followed. Bilingual labelling and the nutrition facts table are required as well.
Are samples offered before the order is placed?
Yes, a side-by-side sample is offered on request. Both types are printed on the same artwork, so the difference is clear before you decide.
5. Is gravure printing recycling friendly?
Recyclable structures are made when compatible films are chosen, and the advantages of gravure printing are kept. For this reason, monomaterial films are often recommended when recycling goals are set.
6. Where to buy personalized gravure printed pouches?
Personalized gravure printed pouches are offered by Universal Packaging, and the advantages of gravure printing are delivered through proofs and sampling. A quote is requested by sharing the artwork, the order volume, and the budget.
Which materials are suitable for gravure printing?
Flexible films with a smooth, treated surface are suitable, such as PET, BOPP, CPP, and PE. Surface treatment is needed so that the ink is bonded firmly, and aluminium foil and laminated structures are also printed.
What is required before a gravure job is started?
An approved artwork file, the film and ink details, and a digital proof are required, and the cylinders are engraved only after approval. Because cylinders are made for a specific design, changes after engraving are costly.
What order volume is demanded for gravure to be cost effective?
In this project, the cost per pouch was calculated at 50,000 pouches per month and was found to be lower for gravure. A minimum run is usually discussed with the printer, since the cost of the cylinders is spread across the whole order.
How long does cylinder preparation take?
It depends on the number of colours and the artwork, and is usually 7 to 14 days. The schedule is confirmed before the order is placed.