Smithers' report focuses on the flexo-gravure showdown

Sean Smyth, a consultant and analyst at Smithers, provides an in-depth assessment in his latest research, The Future of Flexo vs Gravure to 2030. While flexo currently holds the competitive edge, gravure is finding strong growth in specific, high-value markets.

Although gravure dominates in India, flexography is a significantly larger process, valued globally at USD 243 billion in 2025, with a projected CAGR of 3.1% through 2030. Gravure, while smaller at USD 104-billion in 2025, is forecast to grow slightly faster at a 3.3% CAGR over the same period.

Smyth said, "Flexo is the larger market in both value and volume. He added, "However, gravure is growing faster in the most rapidly expanding sectors, which are Asian packaging and industrial/functional printing."

While flexo continues to win market share in competing segments like flexible packaging, labels, and cartons, gravure maintains dominance in decor printing (wallpaper and flooring) and publication printing, and flexo remains the leader in corrugated packaging.

Both processes are investing heavily in automation to counter the challenge of falling run lengths and widespread workforce shortages. In real terms, this means flexo is seeing converging trends in automation, including machine learning and zero-make-ready technology to reduce waste. Robotics and AI are also entering the pressroom, with Brotech’s FF-X530 cited as the first AI-driven flexo press. Prepress is streamlined by Computer-to-Plate (CTP) digital imaging and the shift to non-solvent plate processing. Crucially, hybrid flexo/inkjet presses are becoming standard in labels and are growing in corrugated packaging.

Meanwhile, gravure’s innovation is more incremental, focusing on machine learning for automation and robotic cylinder handling. However, the reliance on older presses running solvent inks, coupled with the complex and costly cylinder preparation process (electroplating, engraving, and chromium plating), limits its flexibility and increases costs.

The twin forces of sustainability and digital printing are reshaping the competitive landscape. The Smithers report alludes to the drive to cut emissions is pushing both processes toward water-based inks. Flexo is further along on sustainability with a clear move from solvent to water-wash systems for platemaking. Gravure, however, faces a greater hurdle as the use of hexavalent chromium in cylinder production is under increasing regulatory scrutiny.

Digital printing is the most disruptive force, especially in labels and packaging, where its speed and suitability for shorter runs are winning market share. Flexo’s response through hybrid presses helps it extend its relevance. Gravure, with its long make-readies and high cylinder costs, is seen as more vulnerable in the short-run market, though digital has yet to challenge its dominance in décor and functional printing.

The report talks about flexo’s edge vs gravure’s niche. Flexography is gaining competitive advantages due to its faster and cheaper prepress, practical in-house platemaking, and superior position on sustainability. Its overall lower cost is a decisive factor as brands continue to push for price reductions.

In terms of growth segments, flexo is eyeing packaging, labels, food and beverage, e-commerce corrugated, and printed electronics; while gravure is strong in Asian packaging (fuelled by rising consumer spending), décor printing (wallpaper, flooring), and functional/industrial printing.

The sectors in decline for Gravure include Publication rotogravure (magazines, catalogues), which is in terminal decline due to the shift to digital media.

Sean Smyth concludes that the future for flexo is "positive but with headwinds." Its resilience will come from hybrid integration, with the future of labels likely to be a flexo-digital combination. Gravure’s overall volume will be sustained by Asian packaging growth, but its long-term future will be tied to high-quality, long-run, and functionally demanding applications where its precision justifies the high infrastructure cost. Both processes must continue to invest to meet sustainability demands and manage raw material cost volatility.