Frank Romano talked about “gravure” at our Print Buyer Boot Camp not so long ago so I thought it made sense to give more information about this printing process. I consider it to be the granddaddy of all processes, thanks to the enormity of the presses themselves.

　　When I think of gravure, I think of very long runs for publications (magazines and newspaper inserts), packaging, and certain products, such as wallpaper. In Boot Camp, Frank taught us that a half a million run for gravure is considered short. The average run is over a million. Another growing application? Shower curtains.

　　We also learned that today there are only three gravure publications printers in North America: RR Donnelley, Quebecor and Quad/Graphics.

　　Many publications, like National Geographic, are part gravure (the long-run editorial section, and offset litho (the short-run geographic ad sections and covers). GAA is the Gravure Association of America. I found a good, concise description of the gravure process on their Web site. And I quote:

　　“Gravure is an advanced, high-tech printing process operating the fastest and widest printing presses in the world. It uses a unique image carrier, a gapless cylinder that can be imaged directly from the digital data. Gravure was the first printing process to employ a totally digital environment. The Gravure Association of America, Inc. promotes the use of the gravure printing process for publication printing, package printing and product (specialty) printing.”

　　Gravure is short for rotogravure. It is a type of intaglio printing process. Intaglio is Italian for carving (loosely). I read somewhere it can be translated as “I cut into.” All you need to know is this: in gravure, the image areas are carved or etched into the surface of the cylinder itself.

　　This cylinder is then bathed in ink, allowing the ink to settle into the etched images. Excess ink is then wiped off the surface of the cylinder by a “doctor” blade. Paper is passed between the inked cylinder and an impression cylinder.

　　Gravure differs from lithography in one key way: in lithography, which is traditional offset printing, the image and non-image areas are both on one surface, or plane. In gravure, the image area is below the surface (etched or engraved). The non-image area is on the surface or plane of the cylinder.

　　The depth of the gravure cell controls the amount of ink per spot, and this provides exceptional color quality for photographic imagery; however, text is somewhat jagged. Gravure is all about the cells or spots.

　　By the way, GAA recently moved its location to Paramus, New Jersey (there I go, promoting my home state again). Their new address is 75 West Century Rd., Paramus, NJ 07652. They are co-located with NAPL, the National Association for Printing Leadership.

　　GAA will conduct a “Basic Gravure Seminar” at Western Michigan University twice this year: March 16-20, 2009 and September 14-18, 2009. The Basic Gravure Seminar teaches state of the art technologies and the latest industry challenges on 26 topics covering the entire gravure printing process.

　　So, if you are relatively new to the industry, this seminar gives you a solid foundation in all areas of the gravure process. Also, the seminar fills knowledge gaps for experienced practitioners who have not been formally trained in the practice of gravure. Download a PDF of the seminar brochure, which contains costs and an overview.