What You Need to Know About Digital Printing in Packaging

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Digital printing is commonly used across a range of different applications.

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You’ve definitely interacted with digital printers before, whether that be at your office, high school or at home.

Commonly used for printing documents, chances are you’ve definitely interacted with digital printers at your office or at home before.

But how does digital printing apply to packaging?

Let’s dive right in!

What is Digital Printing for Packaging?

Digital printing in packaging is the process of transferring a digital file (usually a JPEG or PDF file) directly to a printer for applications on packaging materials.

The digital files are converted into the CMYK color system to communicate more accurate color output from screen to substrate.

Unlike offset printing, digital printers don’t require any manual labor for set up, meaning there are no dies or paper rolls to be installed.

Digital printing is commonly used in packaging for creating cost effective samples and prototypes for custom packaging.

However, digital printing can also be used to create some pretty impactful packaging artwork designs!

The Purpose of Digital Printing in Packaging

Digital printing in packaging is commonly used for cost and time efficiency in manufacturing packaging.

Because of the minimal effort required to use digital printers, they tend to do very well for smaller order runs as set up time and costs are completely cut.

Furthermore, digital printing does extremely well for minimalist packaging designs as it provides a high quality output for less complex artwork.

Short Runs & Sampling

It is typically cheaper to produce small runs in digital printing than offset printing.

When an order of fewer than a hundred pieces is required, digital printing is the way to go!

When it comes to custom packaging samples, digital printing again beats out flexography printing and other conventional forms of printing.

Thanks to its lower costs and faster printing times, it is easier to create package samples with digital printing and then opt for offset printing for your final product.

This way you’re not paying a premium for a sample of your packaging that may need changes and more time in the prototyping stage.

Limitations

The drawback to printing digitally is the loss of image quality and, in some cases, only available in smaller paper sizes.

It cannot print in the PMS Color System, which in turn cannot compete with the color accuracy other printers, like offset and flexographic printing, can produce.

Another disadvantage is the number of stock options.

Digital printing can only be produced on certain types of paper materials, while traditional printing can print on more complex and unique substrates such as corrugated, chipboard, grey boards, and other thicker paper stocks.

Ultimately, digital printing does the best on folding carton and can produce some high quality designs when used sparingly.

What is Flatbed Digital Printing

Flatbed digital printing typically uses an inkjet printer to reproduce digital images.

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Inkjet printing is considered to be the future of digital printing.

The process uses ultraviolet (UV) curable inks to print digital images on flat surfaces.

This process is essential as it can print on numerous surfaces such as wood, metal, glass, and tiles.

The technology can also print on materials that have varying levels of thickness making it more versatile in the printing and packaging world.

The Benefits of Digital Printing

• Consistently higher quality: True digital flatbed technology does have a higher initial cost than its competition, but it does print in greater detail and has a higher level of accuracy & repeatability.

• Environmentally friendly: Flatbed printing is also more eco-friendly than conventional printing as it produces a lower amount of waste cartridges and creates lesser air pollution. It leaves behind a smaller carbon footprint.

• Flexible and low cost: Flatbed printing is excellent for custom and commercial packaging. Its lower cost increases the ease of customization and allows customers to develop their designs at a lower price.

• Quick and efficient production time: It saves a lot of time compared to conventional printing as there is no need to continually change plates considering the technology does not use any plates at all.

Digital printing does not require the usage of plates as offset or traditional printing requires.

The process primarily uses toner and liquid ink.

In many instances of digital printing, unlike conventional ink, the ink used will not permeate the substrate being printed on. The ink creates a thin layer on the surface of the substrate, and the ink further adheres through UV curing or laser heating.

While there are many different printing methods at your disposal, the use of flatbed digital printing is exceptionally effective for small-medium businesses looking to save on their custom packaging investment.

While digital printing is commonly used around the globe, it’s not usually discussed in correlation with packaging.

However, it is an extremely effective method in the packaging industry and saves on a lot of time, especially when working to tight deadlines.

Read more about offset vs digital printing to help you make a well rounded decision.

PakFactory can help you find the best printing method based on your packaging and branding specifications!

Get in contact with us today and get your hands on your very own custom packaging today!

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 or Offset Printing

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.

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Lithography 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: Weprintindia

The 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 Printing

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.

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Compared 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.

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Read: Flexographic v/s Lithographic Printing

Digital or Inkjet 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 & Packaging

Digital 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

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.

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Tooling 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 or Screen Printing

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 Box

What’s Right for You?

The 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.

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