Gravure printing uses heavy metal cylinders coated in chrome — a toxic, expensive process that's increasingly regulated. This project built a replacement: cylinders coated with diamond-like carbon instead of chrome, combined with a way to make cylinders in variable sizes without swapping out hardware. Think of it like switching from lead paint to a modern finish that's tougher, cheaper, and doesn't poison anyone. The team took this to TRL 8, meaning they installed and tested it on actual printing presses.
Gravure printing depends on chrome-plated cylinders — a process that is toxic, expensive, and increasingly restricted by environmental regulation. Producing cylinders in different sizes also requires costly retooling. Printers face rising compliance costs and shrinking margins while competitors in flexo and digital printing gain ground.
The consortium built the Roto-Hybrid Process combining two technologies: Hybrid Cylinder technology for size-variable cylinder production, and a Diamond-Like Carbon coating to replace chrome, copper, and nickel plating. They delivered a pilot installation on an actual printing press, validated through end-user trials.
If you are a packaging printer dealing with rising chrome plating costs and tightening REACH regulations on hexavalent chromium — this project developed a Diamond-Like Carbon coating process that replaces chrome plating entirely. The Roto-Hybrid Process was piloted on an actual press with 5 industry partners across 3 countries, targeting TRL 8 readiness.
If you are a cylinder engraver struggling with the cost and lead time of producing different cylinder sizes for each job — this project developed Hybrid Cylinder technology that enables size-variable cylinder production without retooling. This was validated through trials with end users and designed for licensing and joint venture deployment.
If you are a decorative or publication printer looking to reduce environmental liability from electrolytic plating waste — this project built a complete alternative pre-press process that eliminates copper, nickel, and chrome plating steps. The consortium of 5 SME partners demonstrated the solution in operational conditions.
The project objective states the Roto-Hybrid Process enables 'more cost effective' cylinder production by eliminating electrolytic processes like chrome, copper, and nickel plating. Based on available project data, specific cost comparisons or pricing were not published. Contact the consortium for commercial terms.
Yes. The project delivered a 'Pilot installation on press' as a demonstrated deliverable and targeted TRL 8 — a final prototype in an operational environment. The consortium conducted trials with end users including cylinder engravers and gravure printing firms.
The objective explicitly states the technology owners plan to 'establish joint ventures and licensing deals for wider market uptake.' The consortium is 100% industry with 5 SME partners, suggesting commercial IP is held by the partners. Licensing inquiries should go through the consortium.
The Diamond-Like Carbon coating directly replaces chrome plating and other electrolytic processes. This eliminates the use of hexavalent chromium, which is restricted under REACH regulation. The project positions this as a key environmental benefit for the gravure industry.
Based on available project data, specific switchover timelines were not published. The project ran from December 2016 to May 2019 and achieved pilot installation on press. The Hybrid Cylinder technology was designed to integrate into existing pre-press workflows.
The consortium of 5 industry SMEs across 3 countries (Germany, Netherlands, UK) validated the technology. Trials were conducted with external cylinder engravers and gravure printing firms already engaged with the partners.
This is a purely industry-driven consortium — all 5 partners are SMEs with zero university or research institute involvement, which is unusual and signals strong commercial intent. Partners span 3 countries (Germany, Netherlands, UK), covering major European gravure printing markets. The coordinator PNO Consultants is a well-known EU innovation consultancy, suggesting professional project management. The 100% industry composition and FTI Pilot funding scheme confirm this was designed to bring an existing technology to market, not conduct basic research.
PNO Consultants Limited (UK) — an innovation consultancy coordinating the consortium. Reach out via their company website for licensing or partnership inquiries.
Want an introduction to the Green Gravure consortium? SciTransfer can connect you with the right partner for licensing, joint ventures, or pilot testing.
