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11/11/2025

A gravure cylinder is made up of a steel base, a layer of copper, and a final outer layer of chrome.

The steel base provides rigidity. The copper, a soft metal, is engraved with the pattern or artwork to be printed. Finally, the chrome acts as a hard shell to prevent wear and damage to the engraved artwork.

American Yuncheng Gravure Cylinder can provide, not only gravure engraving, but also steel cylinder bases for printers.

A gravure cylinder is made up of three layers: 1) The base is a steel pipe with a cap (called a “flange”) on each end, which has either a hole (called a “bore”) or a shaft integrated into it.2) Next is a layer of copper. This layer has tiny holes (or “cells”) engraved onto it […]

10/14/2025

What is gravure line screen and how do you choose the best line screen for a print job?

❓ First, What is Line Screen?

Electromechanical gravure engraving uses a diamond stylus that vibrates at a set frequency as the cylinder spins, leaving lines of holes with vertically connecting corners around the cylinder.

Typically measured as LPI (lines per inch) or L/cm (lines per centimeter), line screen (LS) is defined as the number of engraved lines per unit of measure.

However, the measurement is taken along the centers of the cells diagonally according to the angle of the engraving. So for example, if the engraving angle is 30°, then you measure at 30° from horizontal.

If you measure horizontally or vertically, you need to multiply or divide the count by a factor from a screen factor chart corresponding to the angle in order to find the line screen.

In reality though, most printers will never get a ruler and magnifying glass to painstakingly count cells. Rather, the intended line screen is entered into the engraver’s computer at the job setup and then recorded on the job’s spec sheet.

❓How Does Line Screen Affect Ink Volume?

One might think that a cylinder with higher line screen would be able to hold more ink because it has more cells…

But actually the opposite is true.

A cylinder with a low line screen has wider and deeper cells that hold more ink. A cylinder with high line screen has many cells that are smaller and shallower.

❓How Does Line Screen Affect Print Quality?

High line screen is ideal for applications requiring fine detail, subtle tone transitions, and sharp text since the high density of ink dots gives a higher-resolution appearance.

At the same time, high line screen may not print enough ink for deep, saturated colors.

In contrast, low line screen may have a coarse appearance as the ink dots become visible to the naked eye, which is not ideal for fine details.

The advantage of low line screen is that it is good for printing heavy solids and bold colors, and it’s especially useful when opacity is required.

Therefore, if you face issues like faint colors or missing dots, using lower line screen may help. But if you see sawtooth edges on fine lines or have trouble getting ink to dry sufficiently, a higher line screen could help.

➡️ American Yuncheng Gravure Cylinder can work alongside your press team to determine the ideal line screen for every color as well as troubleshoot issues you face on press.

09/23/2025

You can understand gravure cylinder engraving specs even if you aren’t an engineer.

Gravure electromechanical engraving creates rows of inverted pyramid-shaped holes in lines across the cylinder face.

The main engraving specs include:
✅ Line Screen,
✅ Angle,
✅ Stylus,
✅ Wall, and
✅ Channel.

Line Screen is measured in lines per inch (LPI) or lines per centimeter (L/cm). It's the number of lines counted diagonally. If line screen decreases, then cell depth and width increases thereby increasing the cell volume.

Angle, also called compression, relates to the shape of the cell opening at the surface of the cylinder, ranging from 30° to 60°. As angle increases from 30° to 60°, the volume of the cells decreases.

Stylus refers to the angle of the diamond used to engrave cells. It does not affect the width of the cell; it affects only the depth of the cell. Therefore, the sharper the stylus angle, the deeper the cells.

Wall indicates the width of the walls between the cells. Increasing the wall thickness decreases the volume of the cell.

Channel is the width of the connection between cells. Channel cannot be customized as it is directly related to the angle and cell width. For 30°, 45°, and 60° the channel is 15%, 10%, and 2% the width of the cell respectively.

Subscribe and stay tuned for more detail on each of these engraving specs.

08/26/2025

What is BCM and how does it affect rotogravure printing?

BCM stands for Billion Cubic Microns (per square inch) and refers to the volume of ink that one square inch of the surface of a gravure cylinder can hold.

When applying ink, printers are typically concerned with accurate color reproduction, but when applying coatings or adhesives, they focus on the volume of the cylinder.

𝗗𝗲𝘁𝗲𝗿𝗺𝗶𝗻𝗶𝗻𝗴 𝘁𝗵𝗲 𝗿𝗶𝗴𝗵𝘁 𝘃𝗼𝗹𝘂𝗺𝗲 𝗶𝘀 𝗰𝗿𝗶𝘁𝗶𝗰𝗮𝗹.

❌ Too little volume can result in too little coating or adhesive being placed on the substrate.
❌ Too much volume can waste resources and cause difficulty drying the substrate in time for the next step of the process.

Gravure cells, which hold the ink, are shaped like tiny inverted pyramids connected by channels. Therefore, calculating the BCM involves knowing:

✅ Line Screen (lines per inch or lines per cm),
✅ Cell Angle,
✅ Engraving Stylus Angle,
✅ Cell Wall Width, and
✅ Channel Width.

Whereas in the USA printers measure volume by BCM per square inch, in Europe printers measure it by cm³/m².

𝗛𝗲𝗿𝗲’𝘀 𝗵𝗼𝘄 𝘁𝗼 𝗰𝗼𝗻𝘃𝗲𝗿𝘁:

💧 cm³/m² / 1.55 = BCM
💧 BCM * 1.55 = cm³/m²

Theoretically one BCM prints a 1.55 μm layer of ink (and one cm³/m² prints a 1 μm layer of ink). However, in reality, not all of the ink will be able to get out of the cell onto the substrate.

The volume that actually transfers to the substrate depends on the shape of the cells, surface tension of the ink, whether the cylinder is worn, whether the cells have dried ink taking up space in the cells, etc.

American Yuncheng Gravure Cylinder can help printers calculate the right engraving specs to reach the best BCM for the job.

08/12/2025

Are your doctor blades getting damaged on press?

Chipped doctor blades can result in ink splashing and building up on the impression roller, which can damage the roller, so it's critical to prevent breakage.

One common cause of this issue can be solved with careful manufacturing of the gravure cylinder.

During electroplating of the cylinder, high current density areas, typically on the ends of the cylinder, can have uneven deposits of copper and chrome.

Therefore, the cylinder’s copper and chrome is polished during the engraving process, which keeps the face of the cylinder flat and removes burrs.

But the very edge of the cylinder also requires special care to protect the doctor blade. The end of the cylinder is rounded off using a mill or file so that it has a radius of 0.25” to 0.375”.

That way any high spots from the electroplating process are removed, and the doctor blade is given a more gradual transition from where it contacts the cylinder to where it overhangs the edge.

This radius protects the doctor blade, prevents splashing, and keeps you printing longer without having to change out components.

Contact American Yuncheng Gravure Cylinder for resolving any issues you are facing on press.

07/30/2025

Smoothness reduces friction, right?

Wrong! It might seem counterintuitive, but a smooth chrome surface on a gravure cylinder can actually lead to more friction and a shorter lifespan.

Actually a prescribed surface roughness is key to making the cylinder print longer by allowing ink to create a lubricating layer between the cylinder and the doctor blade. The level of roughness should be just enough so that ink will lubricate the blade BUT not print on the substrate.

Here are some key aspects of achieving the optimal surface for rotogravure cylinders:

✅ 𝗖𝗼𝗽𝗽𝗲𝗿 𝗮𝗻𝗱 𝗖𝗵𝗿𝗼𝗺𝗲 𝗣𝗼𝗹𝗶𝘀𝗵 𝗪𝗼𝗿𝗸 𝗧𝗼𝗴𝗲𝘁𝗵𝗲𝗿: The roughness of the copper influences the roughness of the chrome, which follows the surface of the copper like a glove over a hand. That means that to get the perfect cylinder roughness, you must fine-tune the polishing of both the copper and the chrome.
✅ 𝗠𝗶𝗰𝗿𝗼-𝗰𝗿𝗮𝗰𝗸𝘀 𝗔𝗿𝗲 𝗜𝗻𝘁𝗲𝗻𝘁𝗶𝗼𝗻𝗮𝗹: Gravure chrome should have a micro-cracked surface for doctor blade lubrication. Ideally for solvent-based inks it should have between 200-300 micro-cracks per centimeter. For water-based inks, a finer crack pattern, around 790 micro-cracks per centimeter, helps prevent corrosion of the copper. The crack pattern is influenced by electroplating additives.
✅ 𝗖𝗿𝗼𝘀𝘀𝗵𝗮𝘁𝗰𝗵 𝗣𝗼𝗹𝗶𝘀𝗵 𝗥𝗲𝗺𝗼𝘃𝗲𝘀 𝗗𝗲𝗯𝗿𝗶𝘀: If the roughness of the polish has an X-shaped pattern or is diagonal to the circumference, then it helps move impurities in the ink to the edge of the cylinder where it can fall away and get filtered out by the the ink system. Otherwise, debris could get caught under the doctor blade and just keep wearing away at the same spot on the cylinder face.
✅ 𝗜𝗻𝗸 𝗮𝗻𝗱 𝗦𝘂𝗯𝘀𝘁𝗿𝗮𝘁𝗲 𝗗𝗶𝗰𝘁𝗮𝘁𝗲 𝗥𝗼𝘂𝗴𝗵𝗻𝗲𝘀𝘀: The ideal roughness depends on both the ink and the substrate being used. For example, cylinders intended for solvent-based inks typically have a target roughness between 12-28 RZ, while those for water-based inks require a smoother surface. Regarding substrate, paper may call for a range of 12-24 RZ while film calls for a smoother cylinder, around 8-16 RZ.
✅ 𝗧𝗼𝗼 𝗦𝗺𝗼𝗼𝘁𝗵 𝗩𝘀. 𝗧𝗼𝗼 𝗥𝗼𝘂𝗴𝗵: A cylinder that is too smooth can lead to insufficient doctor blade lubrication and chrome wear, especially with solvent inks. On the other hand, if it’s too rough, enough ink can stay on the cylinder to actually transfer ink to the substrate in non-printing areas.

Reach out to American Yuncheng Gravure Cylinder, to help determine and achieve the right surface roughness for your printing application.

07/15/2025

Have you ever wondered how the vibrant packaging on your favorite snacks, decorative gift wrap, or even wallpaper is printed? One of the key technologies behind these products is 𝗴𝗿𝗮𝘃𝘂𝗿𝗲 (𝗔𝗞𝗔 𝗿𝗼𝘁𝗼𝗴𝗿𝗮𝘃𝘂𝗿𝗲) 𝗽𝗿𝗶𝗻𝘁𝗶𝗻𝗴—a classic technique that’s still going strong thanks to constant innovation.

🔎 𝗦𝗼, 𝗪𝗵𝗮𝘁 𝗜𝘀 𝗚𝗿𝗮𝘃𝘂𝗿𝗲 𝗣𝗿𝗶𝗻𝘁𝗶𝗻𝗴?

The key component of gravure is a metal cylinder with tiny, precisely carved cells on its surface.

As this cylinder spins in a printing press, one side dips into a pool of ink while the other presses against a substrate, in other words, the paper or plastic that’s being printed on.

Between the ink pool and the substrate, a metal blade wipes away excess ink from the cylinder face, leaving only the ink trapped in the engraved cells.

When the cylinder rolls over the substrate, the ink transfers onto it, creating sharp, rich images.

🔎 𝗪𝗵𝘆 𝗚𝗿𝗮𝘃𝘂𝗿𝗲?

Gravure printing stands out for its ability to deliver amazing quality at high speeds, making it a great option for large print jobs for national brand food packaging, gift wrap, wallpaper, building materials, stamps, and so on.

The cylinders are incredibly durable, capable of producing millions of impressions.

🔎 𝗪𝗵𝗮𝘁 𝗔𝗯𝗼𝘂𝘁 𝘁𝗵𝗲 𝗙𝘂𝘁𝘂𝗿𝗲?

While methods like digital and flexographic printing are great for smaller and medium-sized print jobs, gravure remains unmatched for efficiency and quality when it comes to printing hundreds of thousands of meters of material.

Further, the industry is always evolving, with advances in ink technology and press design making gravure more sustainable and economical than ever. Therefore not only long, but also shorter print runs, can now be done with gravure for top quality results.

07/01/2025

Could gravure cylinder corrosion be causing your print defects? Prevent it with this key procedure for longer, high-quality printing.

Gravure cylinders are valuable assets. Protection maintains print quality and saves money. One of the simplest ways to extend cylinder life is to clean them immediately after use—while the ink is still wet.

𝙃𝙚𝙧𝙚’𝙨 𝙬𝙝𝙮 𝙩𝙝𝙞𝙨 𝙢𝙖𝙩𝙩𝙚𝙧𝙨:

Gravure chrome has a microcracked surface, which means 𝗺𝗼𝗶𝘀𝘁𝘂𝗿𝗲 𝗰𝗮𝗻 𝘀𝗲𝗲𝗽 𝘁𝗵𝗿𝗼𝘂𝗴𝗵 𝘁𝗼 𝘁𝗵𝗲 𝘂𝗻𝗱𝗲𝗿𝗹𝘆𝗶𝗻𝗴 𝗰𝗼𝗽𝗽𝗲𝗿. If ink is left to dry on the cylinder, it can accelerate copper corrosion, leading to chrome bubbling and flaking. Think print defects and missed customer deadlines!

Further, 𝗼𝗻𝗰𝗲 𝗶𝗻𝗸 𝗱𝗿𝗶𝗲𝘀, 𝗶𝘁 𝗯𝗲𝗰𝗼𝗺𝗲𝘀 𝗺𝘂𝗰𝗵 𝗵𝗮𝗿𝗱𝗲𝗿 𝘁𝗼 𝗿𝗲𝗺𝗼𝘃𝗲, reducing cell volume on your next print job. Dry ink can also dislodge into the ink bath and act as an abrasive, rapidly wearing down the chrome.

In short, neglecting cylinder cleaning immediately after use can lead to more frequent cylinder remakes, unexpected press downtime, and inconsistent print quality.

𝗣𝗿𝗼 𝗧𝗶𝗽: Make cylinder cleaning a standard part of your printing procedure, and ensure your team is trained on the right techniques and cleaning agents. A few extra minutes now can save a fortune in the long run.

Take a moment to review your current cleaning protocols. Are you giving your cylinders the care they deserve?

06/03/2025

Five simple ways to save money as a rotogravure printer.

Gravure printers are always looking for ways to improve quality while reducing waste and unnecessary costs. Here are a few ways printers can optimize their workflows for a better margin on projects.

💰 𝗢𝗽𝘁𝗶𝗺𝗶𝘇𝗲 𝗬𝗼𝘂𝗿 𝗖𝗲𝗹𝗹 𝗩𝗼𝗹𝘂𝗺𝗲: The volume of the cells on a printing cylinder is measured in BCM (billion cubic microns). Having too much volume wastes ink and increases drying time, which reduces max press speed. Experiment to find the right cell volume for your ink, varnish or adhesive, and substrate.
💰 𝗨𝘀𝗲 𝗚𝗿𝗮𝘃𝘂𝗿𝗲 𝗳𝗼𝗿 𝗥𝗲𝗽𝗲𝗮𝘁𝗲𝗱 𝗣𝗿𝗶𝗻𝘁 𝗥𝘂𝗻𝘀: Gravure is highly efficient after beginning a print job. Using gravure for jobs with repeated press runs or longer press runs will lower overall cost per impression.
💰 𝗦𝗮𝘃𝗲 𝗮𝗻𝗱 𝗥𝗲𝘂𝘀𝗲 𝗖𝘆𝗹𝗶𝗻𝗱𝗲𝗿𝘀: New gravure bases are an investment, but they can be reused almost indefinitely. Keep an inventory of base sizes you are likely to have future orders for and reuse them when the orders come in.
💰 𝗘𝘅𝗽𝗲𝗿𝗶𝗺𝗲𝗻𝘁 𝘁𝗼 𝗥𝗲𝗱𝘂𝗰𝗲 𝗪𝗲𝗮𝗿: Several factors can contribute to cylinder wear. If you are experiencing excess wear on your cylinder, check on the relative hardness of your doctor blade and cylinder chrome, talk with the ink supplier to see if the particle size is up to spec, filter the ink, request a crosshatch polish on your cylinder, and increase the cylinders' chrome roughness.
💰 𝗥𝗲𝗰𝗵𝗿𝗼𝗺𝗲 𝗕𝗲𝗳𝗼𝗿𝗲 𝗜𝘁’𝘀 𝗧𝗼𝗼 𝗟𝗮𝘁𝗲: When the chrome layer starts to show wear, it’s important to get the cylinder off the press and have it rechromed. Once the copper starts to show, it’s probably too late for a rechrome, and a full remake will be required.

Evaluating these five points can help you reduce costs and increase efficiency without hurting quality.

05/21/2025

Facing premature gravure cylinder wear? The cause could surprise you.

Gravure cylinder chrome is extremely hard, typically in the range of 800 to 1000 HV or Hardness Vickers (in comparison, pure copper is 44-107 HV and mild steel is 140-280 HV) but the harsh conditions of a gravure press can wear it down quickly. Surprisingly, sometimes a top cause of wear may not be the solid doctor blade or substrate, but the liquid ink.

Here are six effective tips to address cylinder wear due to ink:

💧 𝗙𝗶𝗹𝘁𝗲𝗿 𝘁𝗵𝗲 𝗜𝗻𝗸: Filtering your ink removes foreign particles that can get trapped under the doctor blade and wear down the cylinder.

💧 𝗨𝘀𝗲 𝗠𝗮𝗴𝗻𝗲𝘁𝘀: Placing magnets in your ink system attracts metal particles, keeping them from recirculating and causing damage.

💧 𝗔𝗱𝗷𝘂𝘀𝘁 𝘁𝗵𝗲 𝗖𝗵𝗿𝗼𝗺𝗲 𝗣𝗼𝗹𝗶𝘀𝗵: Aim for a high surface roughness (Rz) with a crosshatch polish. This polish pattern works with the doctor blade's oscillation to move contaminants to the cylinder's edge where they can fall away from the cylinder face.

💧 𝗥𝗲𝗽𝗹𝗮𝗰𝗲 𝘁𝗵𝗲 𝗜𝗻𝗸: Regularly flush your ink system and fill with fresh ink to eliminate contamination.

💧 𝗖𝗼𝗻𝘀𝘂𝗹𝘁 𝘄𝗶𝘁𝗵 𝗬𝗼𝘂𝗿 𝗜𝗻𝗸 𝗦𝘂𝗽𝗽𝗹𝗶𝗲𝗿: If certain inks cause excessive wear, discuss potential adjustments with your supplier and ensure that the pigment particle size is within spec.

💧 𝗖𝗼𝗻𝘀𝗶𝗱𝗲𝗿 𝗕𝗮𝗰𝗸𝘂𝗽 𝗖𝘆𝗹𝗶𝗻𝗱𝗲𝗿𝘀: For inks that consistently cause more wear, especially whites and metallics, having backup cylinders can allow you to switch them out without delaying print jobs.

While liquid ink may seem an unlikely cause for chrome wear, it is actually a significant factor. Implementing these strategies can help minimize expenses and delays in your printing operations.

05/06/2025

♻️ Is Gravure Environmentally Friendly? ♻️

As the printing industry evolves, gravure printing is making strides toward greater environmental responsibility. Here are a few ways gravure reduces its environmental impact:

🍃 𝗥𝗲𝘂𝘀𝗲 𝗰𝘆𝗹𝗶𝗻𝗱𝗲𝗿 𝗯𝗮𝘀𝗲𝘀: Old designs get cut off the cylinder base, and new designs are engraved onto it. A cylinder base can be reused almost indefinitely, making it a valuable asset rather than a consumable.
🍃 𝗥𝗲𝗰𝘆𝗰𝗹𝗲 𝗰𝗼𝗽𝗽𝗲𝗿: Engravers use a lathe to remove copper from used cylinders, and they recycle the valuable metal to reduce waste.
🍃 𝗣𝗿𝗶𝗻𝘁 𝗴𝗿𝗮𝘃𝘂𝗿𝗲 𝗳𝗼𝗿 𝗹𝗼𝗻𝗴 𝗽𝗿𝗶𝗻𝘁 𝗿𝘂𝗻𝘀: Gravure cylinders' hard chrome stands up to long print runs, allowing printers to produce high volumes without replacing printing plates.
🍃 𝗨𝘀𝗲 𝘄𝗮𝘁𝗲𝗿-𝗯𝗮𝘀𝗲𝗱 𝗶𝗻𝗸𝘀: Printers use water-based inks for lower volatile organic compound (VOC) emissions compared to solvent-based alternatives.
🍃 𝗖𝗮𝗽𝘁𝘂𝗿𝗲 𝗮𝗻𝗱 𝗿𝗲𝘂𝘀𝗲 𝘀𝗼𝗹𝘃𝗲𝗻𝘁𝘀: Systems that capture and recycle solvents from solvent-based inks significantly reduce waste and emissions.
🍃 𝗥𝗲𝗰𝘆𝗰𝗹𝗲 𝗼𝗹𝗱 𝗰𝘆𝗹𝗶𝗻𝗱𝗲𝗿 𝗯𝗮𝘀𝗲𝘀: When it’s finally time to say goodbye to an old cylinder base, the steel is recycled.

By adopting these practices and many more, gravure printing is moving towards a more sustainable future while maintaining high-quality output.

Embracing eco-friendly initiatives not only benefits the environment but can also enhance brand reputation and customer loyalty.

02/11/2025

Maximizing Efficiency: Tips for Rotogravure Cylinder Maintenance and Care

A key advantage of gravure is the longevity of the print tools for long and repeated press runs, but you won’t realize those advantages if you don’t properly care for your cylinders!

Here are some tips for maintaining your rotogravure cylinders:

✅ Inspect for Damage: Regular inspections during use are essential to identify signs of wear. Early detection of wear allows for re-chrome, avoiding the need for a more costly re-engraving.
✅ Clean After Use: Cleaning removes ink residue and debris from the cylinder surface. Rule of thumb: if you can see what color of ink the cylinder printed, it’s still not clean enough.
✅ Prepare for Storage: After cleaning the cylinder, ensure that the surface is completely dry. Chrome is a porous surface, so any moisture on the surface can seep in and corrode the underlying copper, which in turn can lead to chrome flaking. Then wrap the cylinders with a protective barrier such as cardboard or blankets to keep them dust free and shielded from contact with hard objects.
✅ Proper Storage: Store cylinders either on storage racks or in crates in a climate-controlled environment to protect them from temperature fluctuations and humidity. Beware of doorways! Areas near doors can have the most extreme temperature changes which cause condensation.

By implementing these tips, you can enhance the performance and longevity of your rotogravure cylinders, ultimately leading to improved efficiency and print quality.

Investing time in proper maintenance not only protects your bottom line but also contributes to the overall success of your printing operations.