BOBST advances gravure printing with metallic reproduction using standard inks

GERMANY – BOBST has unveiled a breakthrough in gravure printing by extending its oneECG (extended colour gamut) technology to reproduce metallic tones, such as gold, silver, and bronze, using standard process inks instead of dedicated metallic inks.

First introduced for gravure in 2019, oneECG standardizes the ink set used across jobs, reducing the need for spot (Pantone) inks and engraved cylinders.

This innovation simplifies operations for converters, significantly cutting ink waste, solvent consumption, and changeover times.

Davide Garavaglia, BOBST’s general manager and head of product lines for gravure, vacuum coating and laminating, noted that the technology has gained strong traction among European gravure printers.

“The ECG process has gained considerable traction because they recognize the crucial benefits this method brings to their business, the industry, and the environment,” he said.

By enabling metallic shades to be digitally matched in prepress and printed with the inks already on the press, oneECG allows converters to handle multiple SKUs and shorter runs in a single production cycle.

The result is fewer press stops, faster changeovers, and shorter drying cycles, enhancing efficiency and sustainability.

The environmental benefits are notable. Eliminating frequent cleaning of metallic inks reduces solvent use and volatile organic compound (VOC) emissions.

The reduced need for specialized inks also lowers raw material use and waste from expired or surplus stock. Additionally, using fewer cylinders lessens resource consumption tied to copper and chrome plating and engraving chemicals.

BOBST attributes oneECG’s success to its advanced register and quality control systems, combined with automation and digitalization across the production workflow.

The system forms a key part of BOBST’s smartGRAVURE concept, which aims to create a fully digitalized gravure production process.

Garavaglia added, “Nearly six years since BOBST first unveiled oneECG for gravure, we continue to develop this technology because it represents the future of packaging production.

“As gravure faces strong competition from flexo, innovations like these enhance its competitiveness and sustainability.”

In a related move, BOBST also introduced the FLEXJET module at Labelexpo Europe 2025 in Barcelona. Designed for digital label production, FLEXJET supports short runs and complex multilayer formats.

According to BOBST, the system can cut start-up time by 60%, reduce waste by 30%, and double output, addressing the industry’s shift, projected at 16.2% between 2022 and 2027, towards short-run, high-customization jobs.

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