A comparative study by Prof. Lutz Engisch from HTWK Leipzig

Rotogravure Printing: A Sustainable Choice Amid Evolving Technologies

Rotogravure printing has long been a cornerstone of high-quality, high-volume printing, recognized for its precision, durability, and compatibility with circular economy principles. In 2022, an initial study assessed the sustainability of rotogravure printing, identifying areas for improvement and laying the groundwork for future innovations. Building on this, a second, more detailed study is currently underway, aiming to evaluate and compare the sustainability of various printing technologies in greater depth. This ongoing research adopts a structured and application-focused approach to uncover actionable strategies for reducing environmental impact.

Strengths and Environmental Challenges

Rotogravure printing boasts several ecological advantages. Its cylinder reusability, compatibility with recyclable materials, and suitability for mono-material substrates position it as an efficient and sustainable choice for packaging and decorative applications. With its ability to deliver consistently high-quality output over long runs, rotogravure minimizes production inefficiencies and waste. Additionally, solvent recovery systems used in modern plants further mitigate environmental impacts.

However, challenges remain. Cylinder production and ink drying processes are energy-intensive and contribute to greenhouse gas (GHG) emissions. Solvent-based inks, though effective, release volatile organic compounds (VOCs). The ongoing study aims to address these areas by identifying innovative technologies and methodologies.

Key Insights from the Current Study

The new study focuses on comparing printing methods based on specific applications rather than generalized technologies. This approach acknowledges that differences in printing methods often involve distinct materials, energy consumption patterns, and product lifecycles.

Focus Areas

  1. Flexible Packaging: Comparing gravure and flexographic printing.
  2. Decorative Printing: Assessing gravure versus inkjet printing.
  3. Packaging and Commercial Printing: Analyzing gravure against offset printing.

Methodology

The study uses a detailed, multi-step process:

  • Scope and Boundaries Definition: Identifying suitable products and determining study parameters.
  • Data Collection: Gathering data on energy consumption, materials, waste, and transportation.
  • Emission Factors Determination: Establishing metrics for calculating CO2 emissions.
  • Calculation and Verification: Computing emissions and validating results through audits.
  • Analysis and Reporting: Providing insights and recommendations based on findings.

Regulatory Context and Environmental Indicators

The study aligns with the EU’s Corporate Sustainability Reporting Directive (CSRD) and Ecodesign for Sustainable Products Regulation (ESPR). These frameworks emphasize transparency, double materiality (considering both the environmental impacts of activities and the risks posed by sustainability challenges), and circular economy principles. Metrics like the Corporate Carbon Footprint (CCF) and Product Carbon Footprint (PCF) are integral to this study, enabling cradle-to-grave assessments of greenhouse gas emissions across various applications.

Early Insights and Expected Outcomes

Initial findings highlight the importance of tailoring sustainability strategies to specific applications. For instance, gravure printing excels in high-quality decorative applications and flexible packaging due to its material efficiency and recyclability. However, offset and inkjet printing may offer advantages in other contexts, such as shorter runs or specific substrate requirements. The study also emphasizes the need for clear boundary definitions to ensure valid comparisons across technologies.

Expected to conclude by 2026, this research aims to provide the industry with a robust framework for evaluating and improving the sustainability of printing processes, supporting informed decision-making and innovation.

Conclusion

Rotogravure printing remains a versatile and sustainable option, particularly for large-scale production. The initial 2022 study revealed promising trends, while the ongoing research promises to deliver comprehensive insights into the ecological impacts of different printing technologies. By focusing on application-specific comparisons and aligning with evolving EU regulations, the study reinforces the potential of rotogravure to adapt and thrive in a sustainability-driven future.

HTWK Leipzig