For gravure to survive and prosper in the future as a major package-printing method will require a combination of both applying new technologies and selling end-user customers on the process' cost-saving benefits versus flexography. That was the gist of more than a dozen presentations during the Packaging and Label Gravure Assn. Global's 8th Technical & Operational Conference, held March 2–4 in Miami. Over 200 gravure-printing professionals attended.

Among gravure's latest "flexo-competitive" technology: presses developed to generate less waste, reduce setup time and boost operator friendliness; new gravure sleeves rivaling the production efficiency of flexo sleeves; breakthrough laser imaging/engraving capabilities; high-density inks; and beta tests of refined UV-curing systems for high-gloss gravure. Participants also were updated on the PLGA Global's pending economic model comparing gravure to flexo.

To have a competitive edge with other print methods, gravure can no longer compete using older press designs, explained Wallace Nard, president of Novaflex, Inc. (Carol Stream, IL). A primary and spare trolley system to speed changeovers is a must for wide-web gravure, and servo-driven, gearless presses for faster registration and a shorter web path are beneficial for all web widths.

A six-part session sought to dispel myths and offer justifications for printers transitioning now to gravure sleeves. Brian Bishop, plant manager for Southern Graphic Systems (Louisville, KY) remarked that sleeves offer a significant advantage to closing the cost/time gap with flexo. Three to four repeats appear to be the right mix for printers to standardize on sleeves, he says, and when comparing components, equipment and process time, gravure gets to press faster and cheaper.

Michelle Fontaine, continuous improvement manager for converter Amgraph Packaging, Inc. (Versailles, CT), spoke on gravure-sleeve economics. Currently, costs are 20 to 50 percent less than traditional hard-base engraved cylinders, and lead times are equal or less than regular turnarounds. If you print one to five different repeat sizes or the same graphics are printed repeatedly, then sleeves are for you, Fontaine says.

The thinking behind gravure sleeves must change, added William Boyd, president of textile printer Transprint USA (Harrisonburg, VA). "It's not a cost-savings with sleeves, but a tax on continuing to use cylinders," Boyd says.

"Art of the American Indian," a set of 10 United States Postal Service stamps converted by Avery Dennison, Security Printing Div. (Clinton, SC), won the Best of Show in the PLGA Global's 2004 Print Quality Awards competition. The set of pressure-sensitive, 37-cent stamps were printed in seven colors plus a water-based, phosphor coating on non-phosphor stamp paper. The finished product reflects the quality that can be achieved by the gravure printing process, says PLGA. Judges commented that for this category, the stamps reflected a couple of notches up in the quality scale. "They are a very well produced set of stamps with excellent illustrations, outstanding register and extremely sharp type," judges said.

This year's competition drew a total of 81 entries, which were each judged via a numerical rating with winners being selected based on a composite score of all the judges. "Art of the American Indian" received a perfect 5.0 cumulative rating.

Overall, the competition bestowed 37 awards in 32 categories, including five honorable mentions. Because of a large increase in the number of entries from foreign converters this year, the PLGA also decided to award its first International Print Quality Awards. Winners in seven categories were named.

For complete information on all the winners, go to www.plga.com