Flexible packaging is booming, thanks to its versatility and cost-efficiency. In today’s competitive market, packaging design can make or break a brand. The right printing method not only enhances visual appeal but also impacts durability, production speed, and costs.
Two popular printing methods dominate the industry: digital printing and flexographic (flexo) printing. Each has its strengths, suited to different needs like small-batch customization or large-scale production.
In this article, I’ll break down the key differences, pros, and cons of digital and flexo printing. By the end, you’ll have the insights you need to choose the best option for your packaging goals.
Flexographic printing, or flexo, is a high-speed printing method that uses flexible relief plates to transfer ink onto various materials.
It's widely used in flexible pouch packaging due to its ability to handle diverse substrates and produce durable prints.
Flexo printing begins with creating photopolymer plates that carry the design.
These plates are mounted on press cylinders. Ink is transferred via anilox rollers, which control ink flow for precise application.
The substrate—such as films, foils, or laminates—is fed through the press, where the inked plates transfer the design. The process is fast and efficient, making it ideal for large-scale production.
Flexo printing excels in high-volume production with durable and versatile results but may not suit projects requiring flexibility or quick turnarounds.
Digital printing is a modern printing method that uses inkjet or laser technology to apply designs directly onto flexible packaging materials.
Unlike traditional methods, it doesn’t require plates, making it a go-to option for short runs and personalized designs.
Digital printing uses advanced direct-to-substrate technology. The design file is sent directly to the printer, which applies ink or toner onto the material.
This process allows for variable data printing (VDP), enabling unique elements like serial numbers or personalized graphics on each package without additional setup.
Digital printing is ideal for small batches, custom designs, and high-quality visuals but may fall short for large-scale production or packaging requiring specialty finishes.
When deciding between flexographic and digital printing for flexible packaging printing choice, it’s essential to weigh their strengths across key factors like cost, quality, material compatibility, environmental impact, and setup time.
Here’s how they stack up side by side.
Flexo printing offers lower per-unit costs for large runs, while digital printing eliminates setup fees, making it ideal for smaller orders.
Flexo becomes more cost-effective as order volumes increase, while digital shines for short runs or prototypes.
Digital printing excels in producing gradients, fine details, and photorealistic images, making it ideal for intricate designs. Flexo printing provides consistent results for solid colors and bold designs.
If your design relies on high-resolution imagery or frequent changes, digital is the better choice. For simple designs at scale, flexo is more reliable.
Flexo printing is highly versatile and works well with stretchable rollstock films and textured materials commonly found in flexible packaging. Digital printing has made strides in handling materials like PET and BOPP films, which are popular for snack packaging.
Both methods offer eco-friendly benefits but in different ways.
Each method supports sustainability goals but caters to different priorities—ink composition vs. production efficiency.
Digital printing is much faster to set up than flexo, making it ideal for projects with tight deadlines or frequent design changes.
For quick turnarounds or last-minute updates, digital is the clear winner. Flexo requires more time upfront but pays off in long production runs.
This comparison highlights how each method serves distinct needs based on project size, design complexity, material requirements, and environmental considerations.
Real-world examples highlight how flexographic and digital printing cater to different business needs in flexible packaging.
Here are two cases that showcase their unique strengths.
A leading pet food manufacturer producing 500,000 laminated pouches turned to flexographic printing for its high-volume demands.
Flexo’s ability to handle large runs efficiently helped the brand maintain consistent quality while keeping per-unit costs low. The durable prints ensured the pouches could withstand friction and moisture during transport and storage.
Additionally, flexo printing allowed the use of specialty finishes like spot gloss and metallic inks, enhancing the brand’s shelf appeal in a competitive market.
A startup introducing three SKUs of organic tea used digital printing to create personalized packaging with variable QR codes.
Digital printing’s zero setup costs made it affordable for small batches, enabling the company to test its products without overcommitting to inventory. The QR codes provided traceability and interactive marketing opportunities, connecting customers to detailed product information and promotions.
With digital printing, the startup could quickly update designs based on customer feedback or regulatory changes, ensuring agility in a fast-paced market.
These cases illustrate how flexo excels in large-scale production with durable finishes, while digital offers flexibility and customization for smaller, dynamic projects.
Choosing the best printing method for flexible packaging depends on your specific needs, including production volume, design complexity, regulatory requirements, and budget.
Here's a breakdown to guide your decision:
Volume
Design Needs
Regulatory Compliance
Digital Printing: A better choice for industries requiring frequent label updates, like cannabis or food products with changing regulations. Quick turnaround times allow businesses to stay compliant without delays.
Hybrid Approach
For businesses managing multi-SKU orders or varying production volumes, a hybrid approach can combine the strengths of both methods. Use flexo printing for consistent designs across large runs and digital printing for personalized touches or smaller batches within the same project.
Choosing between digital and flexo printing ultimately comes down to your specific business needs. Key factors like budget, production timeline, design complexity, and scalability should guide your decision.
If you’re unsure which method is right for your packaging goals, consulting with experts can help. Reach out to explore your options or request a sample kit to see the possibilities firsthand. The right printing choice will not only meet your current needs but also position your brand for long-term success.
