Gravure is losing package printing market share to Flexo in North America. Closing the cost gap between flexo and gravure is a prerequisite to regaining market share. This could be accomplished by adopting new cylinder technologies that reduce the cost of cylinder preparation and the size of cylinder inventories. This study examined one such technology, RotoHybrid Cylinders. RotoHybrid is new to the gravure industry and has just entered beta testing. Gravure printers would like to understand how RotoHybrid and Conventional Chrome cylinders compare in term of ability to print images. This research assessed image quality differences between conventional Chrome cylinders and two types RotoHybrid cylinders (HCR Type 1 and HCR Type 2) when cylinders are new. For this research, image quality was assessed on the basis of density, dot quality, ability to print fine lines, and ability to print small text.

Two trials were run. The first trial used Chrome and HCR Type 1 cylinders (electromechanically engraved copper on a steel base protected by a Hybrid Chrome Replacement coating). The second trial used Chrome and HCR Type 2 cylinders (electromechanically engraved copper on a resizable polymer layer protected by a Hybrid Chrome Replacement coating).

Both trials demonstrated that RotoHybrid cylinders outperform conventional Chrome cylinders in terms of density and dot quality. Overall, RotoHybrid cylinders demonstrated equal ability to print fine line and small text. Based on these results, RotoHybrid cylinders could create an opportunity for gravure printers to regain market share in package printing.

Library of Congress Subject Headings

Intaglio printing; Flexography; Imaging systems--Image quality

Publication Date


Document Type


Student Type


Degree Name

Print Media (MS)

Department, Program, or Center

School of Media Sciences (CET)


Gregory S. D’Amico

Advisor/Committee Member

Robert J. Eller


RIT – Main Campus

Plan Codes