As a mainstream process in packaging printing, gravure printing has long relied on solvent-based ink systems. With increasingly stringent global environmental regulations, the replacement process of water-based inks is accelerating. This paper deeply analyzes the key technical bottlenecks in the application of water-based inks in gravure printing and explores solutions and development directions.

1. Fluid Performance Adaptability Challenges

The surface tension of water-based inks is generally higher than that of solvent-based systems (typically 38–45 mN/m), leading to insufficient intaglio cell infiltration. Experimental data show that when the difference in surface tension between the ink and the plate material exceeds 5 mN/m, the transfer rate can decrease by over 30%. By compounding glycol ether wetting agents, the surface tension can be reduced to 32 mN/m, but a balance must be struck between drying speed and leveling.
Narrow viscosity control windows present another pain point. High-speed printing requires ink viscosity to be controlled at 15–25 s (Coating-4 Cup), while the thixotropy index (TI value) of water-based systems is 40% higher than that of solvent-based systems, prone to ink misting. Using nanoscale acrylic emulsions with rheological additives can control the TI value within the ideal range of 1.2–1.5.

2. Drying Kinetics Optimization Difficulties

The latent heat of vaporization of water (2257 kJ/kg) is 5.3 times that of ethyl acetate, making traditional hot-air drying inefficient. Theoretical calculations show that at a printing speed of 200 m/min, water-based systems require a drying channel of over 12 m, 60% longer than solvent-based systems. Modular combined drying technology (infrared pre-drying + hot-air main drying + microwave assistance) can reduce unit energy consumption to 1.8 kW·h/kg, saving 35% compared to traditional methods.
Adaptability differences for composite substrates are significant. PET film (surface energy ≈45 mN/m) matches water-based inks well, while BOPP film (32 mN/m) requires corona treatment to achieve a surface energy above 38 mN/m. A newly developed plasma online treatment device can dynamically adjust surface energy at a line speed of 600 m/min.

3. Printing Suitability Balance Mechanism

Resin system selection determines final performance. Comparative tests show that styrene-acrylic emulsions achieve 5B adhesion (ASTM rating) on paper substrates but only 2B on plastics. Introducing epoxy-modified acrylic resins improves plastic adhesion to 4B while increasing water resistance by 300%. Adding waterborne polyurethane dispersions (PUD) enhances abrasion resistance to 300 cycles (Taber test), approaching solvent-based levels.
Maintaining color concentration requires innovative dispersion technology. Ultrafine grinding (particle size D50 <200 nm) with polymeric dispersants allows pigment content to increase to 25% without affecting rheology. After optimization, the L* value of a branded water-based black ink decreases from 28 to 22, achieving solvent-based blackness.

Currently, the market penetration of water-based gravure inks is less than 15%, but technical breakthroughs are expected to raise this to 40% by 2025. Future directions focus on:
① Development of bio-based resins (replacement rate >30%)
② Smart drying systems (50% energy reduction)
③ Digital printing adaptation systems.
Technical innovation requires deep collaboration among printing equipment manufacturers, ink producers, and substrate suppliers to build a new industrial ecosystem.

Recommendation for Zhongzhixing Gravure Water-Based Ink
Zhongzhixing Gravure Water-Based Ink has emerged as a rising star in the eco-friendly ink industry through innovative technology. This product uses a water-based formula with low VOC emissions, strictly adhering to international environmental standards to facilitate green production. Its superior color concentration and fidelity meet high-end printing demands for food packaging, household product labels, and flexible packaging, demonstrating excellent adhesion and weather resistance on PET, PVC, aluminum foil, and other substrates. Optimized printing adaptability ensures fast drying and sharp screen dot clarity, significantly improving production efficiency and yield. As a leading domestic manufacturer, Zhongzhixing provides customized solutions and technical support to help enterprises achieve dual breakthroughs in environmental transformation and cost optimization.