Is Gravure The WORST In Terms of Sustainability?
There’s a common belief in the industry:
Gravure isn’t sustainable.
It’s understandable why people might think that way.
In the past, Gravure relied on environmentally questionable practices, like using Chrome VI and creating new steel bases for every cylinder.
But here’s the thing—that’s no longer the reality.
Gravure Has Come a Long Way
Over the past decade, the Gravure industry has made real progress.
If you think back 20 or 30 years:
A Gravure cylinder could cost over €1,000.
Lead times were 1–2 months.
Workspaces were filled with open chemical tanks, with poor ventilation and little regard for emissions or air quality.
But today? The production environment looks completely different.
Modern cylinder facilities (like ours at 4Packaging) now feature:
↳ Closed stations
↳ Monitored air quality and chemical handling
↳ Strong recycling systems and regulatory oversight
What Sustainability Looks Like Today
Let’s break down some of the concrete changes that make Gravure far more sustainable than many give it credit for.
♻️ Reusable Cylinders
Gravure cylinders can be reused almost endlessly.
Unless damaged intentionally or dropped from great heights, these tools are incredibly durable—often lasting for life when formats remain consistent.
🔄 Closed Material Cycles
We recover, recycle, and reuse materials like steel, copper, and Chrome III.
This circular approach significantly cuts down on waste and raw material use.
💡 Laser-Engraved Cylinders
Laser engraving applies only the exact amount of ink needed, leading to:
↳ Lower ink usage
↳ Less energy required for drying
↳ Smaller environmental impact
🛠️ Low-Waste Production
Gravure’s consistency ensures you don’t need to stop a press mid-run.
Compared to other technologies—where you might need to pause and change plates—Gravure runs can be completed in full, reducing setup waste.
💧 Water-Based Inks & Solvent Recovery
Although still developing in some markets, water-based inks combined with advanced solvent recovery systems show great potential for eco-friendlier printing.
🔁 Learn how Chrome NEO supports cleaner, safer cylinder production
Chrome Alternatives Are the Future
Let’s talk about one of the biggest sustainability concerns: chromium.
The move away from Chrome VI is already happening—and we didn’t want to wait until 2032 (when regulations expire) to act. That’s why we’ve already invested in Chrome NEO, a safer, cleaner alternative that meets evolving industry and political expectations.
Gravure printers and brand owners alike are pushing for this shift.
And the sooner we transition, the sooner we make Gravure more viable and future-ready.
Changing Perception
We understand that Gravure’s image hasn’t caught up with reality.
Many still associate it with outdated processes—but the truth is:
Gravure today is a cleaner, more regulated, and more sustainable printing technology than ever before.
So is Gravure still the least sustainable option?
Or are we holding onto a picture that no longer reflects the current state of the industry?
Final Thought
At 4Packaging, we believe Gravure has the potential to lead the way in creating a circular, efficient, and environmentally responsible future for print.
We’ve made the shift—and we believe others will, too.
The key is transparency, communication, and action.
🌱 Want to learn more about the transition? Explore Chrome NEO here