In this Q&A, Sean Smyth, Smithers consultant and analyst with over 25 years of senior experience across the print and packaging supply chain, assesses the current state of play in flexo and gravure printing. Drawing on his latest research for market research firm Smithers, The Future of Flexo vs Gravure to 2030, Smyth addresses the key technology trends reshaping both processes, identifies the sectors growing strongly and those under pressure, and outlines the challenges both will face over the next five years.

Which printing process is bigger: flexo or gravure?

Flexo is the larger market in both value and volume. However, gravure is growing faster in the most rapidly expanding sectors: Asian packaging and industrial/functional printing. They overlap in flexible packaging, labels and cartons, where flexo is steadily winning share. But they also occupy distinct niches: gravure dominates décor printing and publications (magazines, catalogues and so on), while flexo dominates corrugated. In every application where they compete head-to-head, flexo is growing faster, but gravure leads in the sectors with the fastest absolute growth.

What are the most important technology trends in flexo?

Several converging trends are reshaping flexo. Press automation has advanced significantly through machine learning and zero-make-ready technology, reducing waste as run lengths fall in labels and cartons. Robotics and AI are now driving further efficiency gains – Brotech’s FF-X530 is cited as the first AI-driven flexo press. In prepress, computer-to-plate (CTP) digital imaging and non-solvent plate processing have greatly improved quality, and more converters are bringing platemaking in-house. Extended gamut printing is replacing spot colours, reducing waste and cutting make-ready time. Hybrid flexo/inkjet presses are proliferating in labels and growing in corrugated.

What are the most important technology trends in gravure?

Gravure press innovation is more incremental. Modern presses incorporate machine learning for automation and robotic cylinder handling to improve productivity. Extended gamut is being used in place of spot colours for gravure as well. However, the installed base is dominated by older mechanical presses running solvent inks, and will need to be retired. Cylinder preparation – electroplating, engraving and chromium plating – remains complex and costly, making in-house production difficult and restricting flexibility.

What is driving the shift towards sustainability?

Environmental pressure is accelerating across both processes. Solvent inks are being replaced by water-based formulations to cut VOC emissions. Flexo platemaking is moving away from solvent washing towards water-wash systems. The use of hexavalent chromium in gravure cylinder production is under regulatory scrutiny and alternatives are being investigated. Packaging waste legislation is also impacting pack design, with flow-on effects for print volumes and formats.

How is digital printing affecting both processes?

Digital is the most disruptive competitive force for both, particularly in labels and packaging where shorter runs and faster design changes favour inkjet and toner-based systems. Flexo is responding with hybrid flexo/inkjet presses, which are now standard in labels and emerging in corrugated and flexible packaging. Gravure is more vulnerable because its long make-readies and high cylinder costs make it uncompetitive for short runs. Digital does not yet threaten gravure in décor or functional printing, where run lengths remain high.

Which sectors are growing strongly for flexo?

Packaging and labels are key growth markets, driven by consumer goods, food and beverage, and e-commerce. Corrugated packaging continues to grow with e-commerce, though it is a mature flexo market. Hybrid flexo/digital applications are opening new short-run opportunities. Printed electronics represents a niche but growing area where flexo’s coating capabilities are relevant.

Which sectors are growing strongly for gravure?

Asian packaging is the standout growth driver, particularly in China, India and Southeast Asia where rising consumer spending is fuelling packaging demand. Gravure dominates in décor printing – wallpaper, décor papers and flooring – where colour fidelity on reprints is critical. Functional and industrial printing, including printed electronics and coatings, is also growing.

Which sectors are struggling or in decline?

Publication rotogravure is in terminal decline as magazine, catalogue, directory and brochure print runs collapse with the shift to digital media. This was once one of gravure’s largest segments. Flexo newspapers are also declining sharply. Flexo’s niche in books is falling. Gravure is under structural pressure in short-run labels and flexible packaging where flexo and digital alternatives are more economical.

Which process has the competitive edge going forward?

Flexo’s advantages are accumulating. Prepress is faster and cheaper; plates can be reused; in-house platemaking is practical. Press automation is reducing make-ready waste and the need for skilled operators. Hybrid integration with digital inkjet extends its relevance to shorter runs. It is also better positioned on sustainability – water-based inks and non-solvent platemaking are further along. Overall cost is generally lower than gravure, which is a decisive factor as brands push converters on pricing.

What challenges are common to both processes?

Both processes share several systemic challenges over the next five years. Sustainability demands – emissions control, packaging waste legislation, circular economy requirements – will require ongoing investment and reformulation. Skilled workforce shortages are universal across manufacturing regions, making automation investment a necessity rather than a choice. Raw material cost volatility will remain, driven by supply chain disruptions and commodity pricing. And both processes must navigate the digital disruption of packaging runs without losing their relevance in the segments where their quality and economics remain superior.

What is the overall outlook for flexo and gravure?

The outlook for flexo is positive but with headwinds. It will remain the dominant packaging print process by volume in Western markets and is set to grow further in labels, flexible packaging and corrugated globally. The main risk is the accelerating capability of digital alternatives. Hybrid integration is the industry’s pragmatic response – the future for flexo in labels in particular is likely to be flexo-digital rather than flexo alone. 

Asian packaging growth will sustain overall gravure volume through the forecast period, even as publication gravure shrinks. Décor printing is a reliable and relatively protected niche. Gravure’s future is increasingly tied to high-quality, long-run, and functionally demanding applications where its precision and consistency command a premium that justifies the infrastructure cost.