Reduce Ink Cost in Packaging Printing — Rotogravure & Flexo (Practical Ways)
Ink is one of the biggest variable costs in packaging printing — and most presses use more than the job actually needs. In this 5-minute guide we cover practical, proven ways to reduce ink consumption in both rotogravure and flexo, without losing print quality.
You'll learn where the ink is really being metered (the cylinder in gravure, the anilox in flexo), the levers that cut ink film for the same colour, and the "works-for-both" techniques — GCR, Extended Colour Gamut, a smart ink kitchen and measurement — that deliver the biggest savings. Lower ink cost, better quality, greener packaging.
CHAPTERS
0:00 Why reduce ink cost
0:20 Rotogravure — start at the cylinder (cell structure / HD engraving)
0:40 Electrostatic Assist (ESA) & clean ink transfer
0:55 Doctor blade, viscosity & printing to target density
1:23 Optimise your white ink (often the single biggest saving)
1:38 Substrate treatment & ink holdout
1:51 Connect globally on the GPN App
2:04 Flexo — the anilox rules the ink (right BCM & line-count)
2:23 Keep the anilox clean
2:36 Screen your solids (micro-cell / flat-top plates)
2:51 Kiss impression, chamber blade & high-strength inks
3:29 Works for both — GCR & total area coverage
3:49 Extended Colour Gamut (ECG)
4:02 Smart ink kitchen & measuring ink use
4:28 The ink-saving checklist
4:43 Make your daily work easy — Join GPN
WHO IT'S FOR
Press operators, production & QA managers, printers, converters and packaging brand owners in flexible packaging, cartons, labels and corrugated.
ABOUT GPN
Global Packaging Network puts packaging cost calculators, a global supplier directory, CRM, SCM and RFQ in one app — so you can price a job accurately and connect with buyers and suppliers worldwide.
🌐 Website: https://globalpackagingnetwork.com
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📞 Rajesh Modhvadia, Founder — +91 96500 47650
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Note: techniques shown are general industry best practice; always validate on your own press, inks and substrates.
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