Esko and BOBST have partnered to introduce smartGRAVURE, a digitalized gravure printing solution that significantly reduces downtime and enhances efficiency. The system cuts color matching time in half, minimizes setup-related delays by 70%, and ensures consistent high-quality results.
Developed by BOBST in collaboration with Esko, smartGRAVURE integrates Esko’s AVT SpectraLab XF color measurement technology into BOBST’s gravure presses. This innovation enables automated in-line color control, reducing waste and improving productivity. “Gravure is a stable technology, but we aimed to simplify and digitalize the color adjustment process to enhance efficiency,” said Davide Rossello, BOBST Competence Center Manager.
The partnership, which began in 2019, focused on addressing the challenges faced by gravure printers, including lengthy color adjustment processes and waste from multiple test runs. Esko’s AVT SpectraLab XF, a third-generation ISO-certified measurement device, plays a critical role in this solution. “This technology measures color during press startup and production, allowing operators to ensure consistency and minimize environmental impact,” explained David Naisby, Business Development Director at Esko.
Through integrated software development, the two companies created a seamless workflow where live color data is displayed on BOBST presses. Testing in 2022 demonstrated the system’s accuracy, with color measurements achieving industry-standard tolerances. “With smartGRAVURE, we’ve addressed bottlenecks in color matching, significantly improving setup times and reducing material waste,” said Naisby.
In trials, the system achieved a 94.6% extended color gamut compliance rate. It also cut job changeover times to under 20 minutes by automating adjustments, eliminating the need for extensive cleaning, and reducing test runs. “This innovation ensures consistent color quality while cutting waste by 60%,” added Rossello.
By streamlining the printing process, smartGRAVURE offers gravure printers an efficient and sustainable solution, enabling them to meet evolving industry demands with greater ease and precision.