With retail and ecommerce markets becoming increasingly competitive, brand owners face the imperative to innovate and surpass rivals in various market scenarios. Beyond investing in comprehensive marketing strategies or fortifying in-house customer service teams, businesses discover an avenue for achieving sales quotas—meticulously crafted product packaging.
This entails a fusion of functionality and aesthetics, where graphics and text not only serve a utilitarian purpose but also possess the potential to stand out on shelves and translate into purchases.
The impact of packaging on short-term and long-term profits cannot be overstated. Brands that harness the full potential of product packaging design can convey information effectively while seizing (and holding) consumers’ attention.
This comparative guide aims to unravel the intricacies of various packaging printing methods to empower your brand to make strategic packaging decisions.
In a packaging design process, you’ll need to compare and contrast the various printing methods suitable to your product. There are several packaging printing techniques available, and each of them fits different end-use applications.
For several decades, flexographic printing, commonly referred to as “flexo,” has stood as the preferred method for high-volume product labels and flexible packaging production, particularly in the food and beverage industry. Renowned for its adaptability, flexo employs a flexible relief plate made of rubber wrapped around a cylinder for seamless and efficient printing.
In the flexography process, an anilox roller, a cylinder with microscopic “cells” made of metal or ceramic, transfers ink to the relief plate. As the plate contacts the substrate, the image is transferred at high speeds and low operating costs. Continuous advancements in flexography have introduced greater automation and improved quality that can now rival traditional offset printing.
Flexography emerges as a cost-effective solution for extensive print runs with fewer printing constraints. Its versatility shines, allowing the printing of almost any shape or format—unlike lithography, which necessitates a flat substrate. Ideal for high-speed manufacturing lines, where labels adhere to roll-formed products instead of sheets, flexography excels in achieving high-quality print images and offers the potential for perfectly matched spot colors.
While flexography proves optimal for companies seeking cost-effective solutions, it does present challenges.
Serialization and unique codes can be cost-prohibitive in traditional flexographic printing, especially for low-volume jobs with numerous SKU or design variations. Lower-cost flexographic print providers may struggle to achieve the crisp print quality needed for intricate designs, smooth color gradients, and accurate representations.
As companies weigh the benefits, the limitations of flexography must be carefully considered based on the specific requirements of the packaging project at hand.
Lithography, also known as offset printing, finds widespread application for large or flat items such as custom folding cartons, corrugated packaging, and expansive labels used in packaging and retail displays. In the litho printing process, the image is meticulously set onto an aluminum plate and subsequently transferred to a rubber blanket for processing.
The final step involves the image being printed onto a substrate, with the option for additional finishes such as coatings or varnishes to enhance appearance and provide protective layers.
Lithography stands out for its versatility in printing small to large format sizes, making it well-suited for high-volume production with intricate graphics. Often hailed as the quality standard in package printing, offset litho sets a benchmark against which other processes are measured.
Notably, color-matching achieves exceptional accuracy, and the option for post-print finishes, such as gloss coating or foil embellishment, adds a touch of luxury and quality. In addition to the superior quality and diverse finishing options, offset litho boasts fast printing speeds, contributing to efficient production.
Lithography’s custom-made aluminum plates contribute to relatively higher costs, particularly in shorter print runs. Regardless of volume, most print providers impose setup fees for plate production. This plate cost, coupled with the inherent customization challenges, renders lithography printing cost-prohibitive for brands seeking short runs or versioning.
Gravure printing engraves designs onto metal cylinders. Each cylinder corresponds to a specific color, and the printing machine meticulously applies ink, slowly generating a high-quality image. Primarily recommended for detailed packaging designs, gravure is a prevalent choice for food products packaged in flexible materials.
Gravure’s superior image quality and durability give it an advantage in ultra-high volume print jobs where lithography and flexography would be slower and prone to reduced image quality over time. Strategic collaboration with a reliable custom packaging supplier enables production at high speed and low running costs, all without compromising quality.
Gravure printing presents challenges for projects with low print quantities, as its setup can be relatively expensive. The setup process for gravure print jobs is time-intensive, often spanning weeks and incurring costs in the tens of thousands of dollars. Consequently, gravure proves most effective for projects that involve millions of units with minimal changes to graphics or text copy.
Brands seeking versatility or those not producing packages in large volumes may find digital printing to be a more cost-effective and flexible alternative.
Digital printing has rapidly gained traction in product packaging, evolving and improving swiftly compared to traditional methods such as flexo, offset, and gravure. While relatively new, digital printing, particularly inkjet technology, is becoming a mainstream choice due to its faster speeds, lower running costs, and enhanced print quality.
Digital printing’s versatility extends across various products and surfaces, with particular prominence in corrugated packaging and folding cartons. Once considered as complementary technology to conventional printing methods, digital printing has now emerged as a viable mainstream alternative for short-, medium-, and long-run packaging.
In lower quantities, digital printing proves more cost-efficient than its analog counterparts. Some printers offer hybrid flexographic/digital printing options, combining the precision of flexo with the variability of digital printing. Notably, digital printing excels in creating versioned images, variable data, and personalized packaging—embracing trends that have reshaped the packaging landscape.
Digital printing systems like the HP Indigo Digital Press showcase extraordinary quality on diverse packaging substrates such as flexible packaging, including shrink sleeves and labels. The technology enables mass customization, versioning, serialization, and efficient unique coding, providing brands with cost-effective solutions for tailored packaging.
While digital printing excels in flexibility and efficiency for shorter runs, it may not match the unit economics of analog printing technologies in very long runs, ranging in the hundreds of thousands or millions. For extensive print quantities, flexo, gravure, and litho may offer more economically viable alternatives.
The reliance on combinations of tiny ink dots makes achieving a perfectly matched, smooth color challenging in digital printing. Brands that prioritize near-perfect color matching for logos or other brand elements may opt for other packaging print methods to ensure precise color reproduction. Understanding these trade-offs becomes crucial for brands seeking the optimal balance of packaging costs, customization, and print quality.
True to its name, screen printing creates designs using a woven silkscreen. Specific areas of the fabric are coated with a non-permeable material, leaving the rest open for ink application. Since the printing surfaces do not need to be flat, the method adapts to a diverse range of materials. This includes paper, fabric, glass, and metal, making it a versatile choice in the printing landscape.
Screen printing distinguishes itself by being best suited for small-scale jobs, offering a cost-effective solution with relatively low setup costs. Its adaptability to non-flat surfaces makes it suitable for various materials, providing flexibility in design and application.
While screen printing proves economical for smaller projects, its production speed is not optimal for large-scale businesses. The method’s relatively slow production time may pose challenges for heavy-volume requirements. In such cases, opting for offset lithography, flexography, or gravure printing might be more conducive to meeting the demands of larger production quantities.
Each packaging printing technique brings its distinct advantages and challenges. There is no one-size-fits-all solution, and the key lies in understanding how each method operates to determine the best fit for your business. This knowledge empowers your brand to make informed decisions aligned with your specific packaging requirements, whether you prioritize cost efficiency, intricate design details, or production speed.
Should you find yourself navigating the complexities of packaging printing, consider consulting with experts in the field. Meyers has a team of seasoned professionals ready to cater to your unique printing needs.
Talk to our experts and start your journey to compelling custom packaging solutions. Discover the most fitting solution for your business, ensuring that your packaging not only meets industry standards but also stands out in a competitive market.
Packaging printing can be an extensive subject and picking the right type of printing can be quite confusing if you are not aware of the processes as well as the pros and cons. When you ask for a quote to your packaging manufacturer, you are only limited to the printing technology that they have access to. However, your decision should not be limited by that. Since cartons are rigid and flat, you can get a lot of printing options that other flexible packaging materials do not have. Here are some of the common printing technologies that are available for printing cartons.
Lithography is used for most modern-day bulk printing jobs. Manufacturers use printing plates for lithography. The plates are inked and then pressed onto the paper for printing. Modern-day lithography uses rollers instead of printing plates. The rollers contain the negative of the image that is made by exposing an emulsion t ultraviolet light. Lithography is mostly used to print folding cartons as well as labels, which are also referred to as litho labels.
Image Courtesy: PinterestLithography provides you with retail-quality printing. Cosmetic boxes, electronic products, and food packaging printing make use of lithographic technology. Lithography has very high print quality. More than four colors can be used in lithography. However, 1 or 2 colors are used commonly. Lithography also allows special coatings to be applied. This gives the product packaging an up-market look. It can be used to give a soft matte touch or a high gloss look. Lithography also produces smooth color gradients where banding is not noticeable.
Image Courtesy: WeprintindiaThe biggest drawback with lithography is the tooling cost and the lead time. To make sure that the costs stay low, one has to order high volumes of printing. Many lithographers have a high minimum number of prints that you have to order. Also, lithography printing can only be done on flat surfaces.
Flexography is commonly used for stand-up pouches. However, manufacturers use it for corrugated boxes too. The method is quite similar to that of Lithography, but instead of flat plates, a flexography uses a light-sensitive polymer. A 3D relief is prepared which is then mounted on a roller to print the graphic. In Flexographic printing, your cost of printing will go down. Plus, tooling costs are much lower. Only the plate needs to be prepared. It has faster turnaround time and can use both water and oil-based inks.
Image Courtesy: Technology StudentCompared to lithography printing, flexography has noticeably lower printing quality. It cannot be used for printing photo quality images. Moreover, while printing smooth colors or gradients, flexographic printing has visible banding. Registration with 4 color processes is also much more difficult.
Image Courtesy: SmithersRead: Flexographic v/s Lithographic Printing
Digital printing is extensively used in small-scale print jobs. When it comes to paper products, digital printing is used quite a lot. Labels, films for flexible packaging, folding paper cartons, corrugated boxes – all of them use digital printing. Even packaging prototypes make use of digital printing.
Digital printing is quite easily accessible. This is because it comes with zero tooling costs. No prior setup is required. You can just go to the manufacturer with a design and get it printed right there. Most printing companies also have a low minimum order quantity when it comes to digital prints. It has quick turnaround times and with the correct configuration, it gives printing quality that is comparable to lithographic printing.
Image Courtesy: Digital Labels & PackagingDigital packaging printing is inconvenient to print in large volumes. This is mostly because it takes a lot of time to print a single sheet. Moreover, digital printing requires color calibration. Digital printing does not come with any protection, like lithographic printing. Moreover, digital costs cannot use metallic inks and per unit costs are quite high, compared to lithographic or flexographic printing.
Rotogravure is typically used for stand-up pouches. Folding cartons also use this technique. Rotogravure process consists of an engraved cylinder that is used to transfer the ink to the substrate. The engraved cylinder presses the paper or film onto the gravure cylinder which is smeared with the ink. Rotogravure is not very common when compared to flexographic or lithographic printing, but is still used in commercial printing. It can provide premium quality prints with calibrated colors, has 4 color process and can easily add PMS colors. Rotogravure printing also provides very long lasting prints.
Image Courtesy: IndiaMARTTooling costs are quite high in this process of printing. Therefore, if you are investing in this process, you better order a high print volume. The complicated tooling also increases the lead times.
Silkscreen is used for printing labels, folding cartons, promotional items and also for prototypes. It is a great option for custom packaging printing especially when the packaging is made independently. This includes caps and bottles, custom-made mugs and shirts. The set-up cost is also quite minimal. A polymer mesh is used to transfer the ink to the substrate. Here, the mesh acts as a stencil. A squeegee is used transfer the ink through the mesh and onto the surface. Silkscreen can also be used for smaller volumes and does not always need a flat surface.
The production speed with silkscreen is much lower. A lot of the process requires manual effort and hence human error may screen in. Moreover, the print quality is quite low, colors are not accurate and is not a good option for high volume printing.
Image Courtesy: Shanghai DE Printed BoxThe best printing solution depends on your requirements and your budget. If you want high-quality prints with accurate colors, flexography should be your first preference, followed by lithography. For smaller volumes, you can also go for digital printing. If color accuracy is of utmost importance to you, then you can go for Rotogravure printing too. A silk screen is a good option for low cost and low volume projects.
Contact us to discuss your requirements of Pre roll CR tin box china, kush supply company, Cannabis Packaging Solution. Our experienced sales team can help you identify the options that best suit your needs.