Can Gravure Printing Use Water-Based Inks?

Date: Mar 12 2025 From: Star Color

Amid the global printing industry’s accelerated shift toward green practices, gravure printing—a technology dominating over half of the packaging market—faces unprecedented environmental scrutiny. Traditional solvent-based inks, containing volatile organic compounds (VOCs) like benzene and esters, have long been criticized for polluting the environment and endangering worker health. Water-based inks, which use water as a solvent and reduce VOC content to below 5%, seem like an ideal replacement. Yet a paradox persists: Why does solvent-based ink still "monopolize" the high-end gravure printing market? Can water-based inks overcome technical barriers? Below, we analyze these questions in detail.

‌I. Gravure’s Core Mechanics & Solvent Inks’ Dominance‌

Gravure printing relies on "recessed ink reservoirs." Laser-engraved or chemically etched cells on a metal cylinder hold ink, which is transferred to substrates after excess ink is scraped off. This process achieves high-definition prints (150+ lines per inch), making it the preferred choice for luxury packaging like cigarette boxes, cosmetics, and food-grade films.

Solvent-based inks dominate due to two key advantages:

‌Drying Speed‌: Solvents evaporate in 2–3 seconds at 80–120°C, enabling speeds up to 400 meters/minute.
‌Adhesion‌: Solvents slightly corrode plastic surfaces, ensuring strong bonding with polyethylene (PE) and polypropylene (PP).

This efficiency comes at a cost: A single gravure press emits ~10 tons of VOCs annually, with 20–30% of ink expenses allocated to waste-gas treatment.
Can Gravure Printing Use Water-Based Inks?

‌II. Water-Based Inks in Practice‌

In 2018, a global beverage brand adopted water-based inks for its paper packaging, marking a milestone in industrial application. Benefits include:

‌90% lower VOC emissions‌ and ‌FDA-compliant safety‌, eliminating solvent migration risks.
‌High pigment concentration‌ (up to 40%), delivering vibrant colors with less ink.
‌Recyclability‌: Water-based PET labels allow easier ink separation, boosting recycled material purity by 15%.

‌Technical Challenges‌:

‌Flow Limitations‌: Water-based inks (30–50s viscosity, Ford Cup #4) struggle to fill gravure cells, causing 10–15% coverage loss ("white spots").
‌Drying Delays‌: Water’s high latent heat extends drying to 8–10 seconds, capping speeds at 150 meters/minute.
‌Adhesion Issues‌: Untreated PE films achieve only 70% adhesion (vs. industry-standard 90%).

‌Solutions‌:

Adding 5–8% ethanol to accelerate drying.
Nanosilica additives (particle size <50nm) reduce viscosity to 25s.
Corona treatment (surface energy ≥38mN/m) improves adhesion to 85%.
"Reverse printing" (inking film interiors) protects layers via lamination.

‌III. Cost-Benefit Analysis‌

Despite technical progress, economic factors remain critical:

‌Upfront Costs‌: Corona treaters (¥200,000) and dryer retrofits (¥300,000–500,000) deter SMEs.
‌Long-Term Savings‌: Water-based inks cost 15% more upfront but cut solvent purchases by 30% and waste treatment by 50%, with ROI in 2 years.
‌Compliance‌: Meets EU REACH and China’s green packaging standards, safeguarding export orders.

A Guangdong-based printer reported annual savings of ¥800,000 in waste fees and 5–8% product premium post-conversion.

IV. Future Frontiers: Speed & Performance‌

Key hurdles remain:

‌Speed Limits‌: Hybrid drying barely reaches 200 meters/minute (vs. solvent’s 400).
‌Material Compatibility‌: Poor performance on metallized films and shrink sleeves.

‌Innovation Pathways‌:

‌Hybrid UV-Water Inks‌: UV-curable resins enable 0.5-second curing.
‌Digital Gravure‌: E-beam engraving reduces solvent use by 30% (experimental).
‌AI-Driven Drying‌: Sensors optimize oven humidity/temperature, cutting energy use by 20%.

Can Gravure Printing Use Water-Based Inks?

‌Conclusion‌

Water-based inks for gravure printing are considered mature, and in the short term, paper packaging and printing processes are the priority areas for replacement; In the long run, it is necessary to collaborate with ink factories in the industrial chain to optimize formulas, equipment manufacturers to develop specialized models, and policy providers to provide tax incentives.

‌Zhongzhixing Colors‌, a leader in water-based ink R&D, has achieved breakthroughs:

Nanoscale resin dispersion stabilizes viscosity at 25–30s (Ford Cup #4).
Rheology additives optimize surface tension, boosting speeds to 200 meters/minute.

For gravure printers seeking sustainable solutions, contact us to explore tailored water-based ink systems.