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Businesses are facing the issue of uniqueness in the competitive e-commerce and retail markets. It’s vital to differentiate products using custom packaging in the market to capture potential customers and boost sales. There are different printing methods for various types of packaging, offering short-term and long-term benefits. Let’s explore types of printing such as offset, digital, flexographic, rotogravure, and screen printing options.

Offset Printing

Lithography or offset printing is an older method combining offset and lithography. It is included in versatile kinds of printing, offering non-variable prints in the presence of one or more colors. Lithography is an ideal method for larger volumes of packaging solutions such as custom corrugated boxes or folding cartons.

Lithography Printing Process

The image is transferred on an aluminum plate before proceeding to the rubber sheet. Now, the image will be moved onto the substrate in the presence of additional finishing options like varnishes or coatings. 

Advantages of Offset Printing

  • Versatile printing method for small to large volumes.
  • Intricate designs for the high-volume production.
  • A benchmark against other printing options to premium quality standards.  
  • Top-notch color accuracy for packaging elegance.
  • A luxurious touch in the presence of post-print finishes like foil embellishment.
  • Offset package printing offers quick production.

Disadvantages of Offset Printing

  • Higher startup costs.
  • Expensive option for low-volume production.
  • Customization difficulties.

Digital Printing

Digital printing for packaging is an efficient and accurate option due to the use of inkjet technology. This inkjet printing method transfers the image directly to the packaging material without using a medium. This quick printing method offers improved quality with lower

 expenses. 

Inkjet Printing Process

In the digital printing process, an image is moved directly to the printing surface of a packaging. A laser or inkjet printer is preferred to streamline the transferring of ink smoothly. 

Advantages of Digital Printing

  • Lower setup costs for this printing method.
  • Versatile printing method for different surfaces and products like custom printed packaging.
  • Flexible packaging printing method for small volumes.
  • Affordable printing choice for lower quantities.
  • Variable printing in the presence of printers offering hybrid digital/flexo printing options. 
  • Best option for customizable packaging, variable data, and detailed images.
  • Availability of extraordinary quality on diverse substrates like flexible boxes.
  • No minimum order quantity ensures waste reduction.
  • On-demand and eco-friendly printing choice.
  • Flexibility of editing prints for modification purposes.
  • Lower labor costs and errors.

Disadvantages of Digital Printing

  • Unsuitable option for larger volumes.
  • Difficult to achieve a smooth color combination.
  • Limited paper options because digital printing can’t work with certain papers.
  • Limited finishing options.
  • Size limitation for producing prints.

Flexographic Printing

Flexo printing is one of the different printing methods ideal for fixable and high-volume purposes. This printing technique uses a flexible relief plate in the process to ensure phenomenal and seamless printing due to the presence of a cylinder. This printing option is ideal for higher volumes and can print one or more colors. The perfect printing choice for recurring orders of printing a product packaging design.

Flexo Printing Process

A flexible relief rubber plate is used in the printing process. A cylinder and an anilox roller transfer the image to the relief plate. Flexography offers the transferring of images at an affordable cost and quickest rate.

Advantages of Flexographic Printing

  • Affordable printing option for larger print runs with a few modifications.
  • Versatile printing choice for a variety of formats or shapes.
  • Perfect for quick manufacturing lines to achieve premium print images.
  • Ideal for matching this printing with the different colors.
  • The ability to print multiple materials easily.
  • Sustainable printing method with lower setup costs.

Disadvantages of Flexographic Printing

  • Limitation for fine-tone details.
  • Inconsistent printing quality depends on the material.
  • Sufficient time and cost are required for setup. 

Screen Printing

It is one of the different printing styles where an image is transferred to a material surface through the mesh screen that is coated with a design or stencil. Silkscreen printing ensures elegant designs for diverse materials like metal, fabric, and paper.

Silk Screen Printing Process

In this printing method, specific parts of a material feature coating with impenetrable material while leaving the surface open for the application of an image or ink. Ink is transferred to the screen and the presence of a squeegee ensures moving of design onto a substrate seamlessly. 

Advantages of Screen Printing

  • Ideal printing method to ensure durable prints.
  • Utilization of vibrant colors to create perfect designs.
  • Assurance of a larger printing area to accommodate different design sizes easily.
  • Top-notch option for custom prints for different purposes.
  • An affordable option for high-volume reducing branding package cost.

If you are worried how much actually cost of your branding package, you can explore our comprehensive article: How much packaging cost

Disadvantages of Screen Printing

  • High setup costs, including the creation of stencils and screens.
  • Resolution limitation for photographic images.
  • Color complexity issues as each color demands a separate printing pass and screen.

Rotogravure Printing

This printing technique moves the designs onto metal cylinders. Each cylinder aligns with the specific color scheme during the ink application through the printing machine. Gravure is one of the various types of printing that ensure premium image quality through a slower process. 

Gravure Printing Process

It is a fantastic printing method in which each image is used on the cylinder. The cylinder is coated with the ink, which will be transferred to the material during the pressing process. The images will maintain consistent color quality on different packaging materials.

Advantages of Rotogravure Printing

  • High-quality and durable prints with consistent color reproduction.
  • Efficient printing for the long run.
  • Versatile printing on different materials.
  • Quickest production time, ensuring on-time production of large-scale production.
  • Lower running expenses while maintaining fine details.

Disadvantages of Rotogravure Printing

  • Longer setup time.
  • Higher initial costs.
  • Cylinder tear and wear.

Get Packaging Printing Done by The Box Zilla

There is no all-in-one solution because each printing method has its own benefits and drawbacks. Let’s get the help of our professional packaging experts, who can help print your packaging effectively to make a difference in a competitive market!

For free design assistance and a detailed overview of our printing process, please feel free to contact us via email at sales@theboxzilla.com or call us at +1 888 668 1241. We are committed to delivering the highest quality results for your packaging needs.