Resources · Free tool
Flexo vs Gravure — cost comparison.
Price the same pouch job on both processes. We'll show the per-pouch cost of each, which wins, and the break-even volume — so you choose the right process for the run.
Indicative estimate · for guidance only
How it works
How the comparison works
The tool prices one pouch job twice, on a flexo press and on a gravure press, using the same cost lines for both. Most of the difference comes from tooling: flexo plates are cheap to make, gravure cylinders are not.
- Tooling
- Flexo plates and gravure cylinders, each priced by area and number of colours. This fixed cost is what decides the break-even.
- Material and ink
- The film by thickness and density, and ink by colour, coverage and price, for each process.
- Machine time
- Run time at each press's speed plus set-up and changeover, charged for electricity, manpower and the press itself, with its price turned into an EMI at 10% a year over 7 years.
- Gravure drying gas
- The gravure dryer's gas use and rate, spread across its jobs each month.
- Break-even
- The order quantity where both processes cost the same per pouch. Below it, the process with lower tooling wins.
If flexo wins for your runs, the Nova A8 prints film and flexible packaging from 8 to 450 µ on webs up to 670 mm wide.
FAQ
Flexo vs gravure — questions
Is flexo or gravure cheaper?
It depends on the job. Gravure has higher cylinder (tooling) costs but runs efficiently at very high volumes, while flexo has lower set-up so it's usually cheaper for short and medium runs. This tool prices the same pouch on both and shows the break-even quantity where one overtakes the other.
What is the break-even quantity?
It's the order quantity at which the two processes cost the same per pouch. Below it the lower-tooling process (usually flexo) is cheaper; above it the other can win. The tool calculates it from your inputs.
Is this comparison tool free?
Yes. Enter one job, see both per-pouch costs and the verdict on screen, and get the full breakdown by email — free.
How accurate is it?
It's an indicative comparison based on your inputs and typical rates, for guidance. Share your job details and we'll firm up the numbers.
Why is gravure tooling so expensive?
Gravure prints from engraved metal cylinders, one per colour, and each costs far more to make than a flexo photopolymer plate. On a long repeat run that cost is spread thin; on a short run it dominates the price of every pouch.
When does gravure make sense?
Very long runs and repeat orders, where the same cylinders are reused many times. For short and medium runs, frequent design changes and many SKUs, flexo is usually cheaper. The break-even quantity in this tool shows where the line falls for your job.
Can flexo print pouches to gravure quality?
For many flexible-packaging jobs, yes. Modern servo flexo presses with high-definition plates and fine anilox rolls can print close to gravure. Very fine vignettes and some metallic effects remain gravure strengths.