Everything You Need To Know To Find The Best Printing and Packaging Solutions

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. 

With competitive price and timely delivery, uprintingplus sincerely hope to be your supplier and partner.

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. 

Types of Packaging Printing Methods

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.

1. Flexography

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.

Advantages

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.

Disadvantages

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.

2. Lithography

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.

Advantages

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.

Disadvantages

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.

3. Gravure

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.

Advantages

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.

Disadvantages

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.

4. Digital printing

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.

Advantages

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.

Disadvantages 

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.

5. Screen printing

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.

Advantages

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.

Disadvantages

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.

Want more information on Printing and Packaging Solutions? Feel free to contact us.

Packaging and Printing Done the Right Way

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. 

Custom printed packaging is an important marketing strategy for any business. It's used to create brand recognition and brand recall, to share important product information and it can make for a memorable customer experience. And what allows businesses to create this packaging, is access to a variety of printing techniques that can deliver. At Sourceful, we work directly with manufacturers to supply businesses with the best packaging solutions and to ensure a high standard offering. And this includes giving customers access to high-quality printing techniques online in our Shop, including those usually only available offline.

Here's a guide to our different printing techniques.

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Flexographic printing

Flexographic printing, also known as flexo, is a versatile printing process used to print on plastic, paper, corrugated material and more. It involves using flexible printing plates that are wrapped around rolling cylinders. These plates are customised with your chosen artwork and rotated at high speeds to directly transfer ink to your packaging. Both solvent-based inks and water-based inks can be used in flexography, though the latter is more popular due to its non-toxicity. The carbon footprint of solvent-based inks is on average 130-150% higher than water-based inks*. As the printing plates are slightly raised, flexography is often referred to as a modern-day letterpress.

Typically available as an offline request, we've worked with suppliers to bring flexographic printing online. We offer flexo for products like gummed tape, self-adhesive tape and shipping boxes in our Shop, as these tend to have simple, bold designs. The result is a product with a high-quality print and strong ink coverage.

Key benefits:

• Most economical and cost-effective option for high-volume print runs.
• Can be used on almost any flexible material, coated and uncoated, such as gummed tape, mailer bags and clothing pouch bags.
• Ideal for printing bold, straightforward designs or simpler graphics and text.
• Best suited for designs using 1-3 colours.
• Colours can be matched to Pantone and GCMI colours.
• Uses fast-drying inks, which means a fast production time and it's safe for food packaging.
• Higher-order quantities can drastically reduce the impact of the printing on a per-unit basis. This is because the impact of the plate and the setup waste are fixed regardless of the order size.

Drawbacks:

• Flexo printing plates are made from photopolymer, the majority of which require setup and washing processes that utilise high impact solvents. These plates can affect up to 60% of the total impact of flexographic printing when produced through solvent-based processing.
• Each colour requires its own printing plate, so multi-colour designs are more expensive and have a higher carbon footprint.
• Large-sized products will have a higher impact as these require larger flexo printing plates.
• More intricate designs and finer details can lose resolution in print, especially on materials with high absorption such as uncoated paper.

*By comparing the ink specifications from our suppliers we found that on average, 1 kilo of solvent-based ink has a 130-150% higher carbon footprint than 1 kilo of water-based inks.

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Offset lithography printing

Offset lithographic printing, also known as offset printing, is the standard method used for high-volume, high-quality printing. It involves transferring your artwork from a computer onto an aluminium printing plate using a laser, which results in a high-quality print due to the laser's precision. It's known as offset print because your artwork is not transferred directly from the printing plate to your packaging, but to an in-between rubber 'blanket' surface first. Whilst offset printing is a versatile process, it's unable to print on corrugated board as the material is too thick for the printing press. So for a product like mailer box, the design is instead printed onto a sheet of paper which is then laminated onto the board. This results in a high-quality print finish for your artwork and allows the structure and fluting of your box to remain intact as it hasn't been pushed through the press. It also means that more print finish options, such as a UV varnish finish, are available for your mailer box.

We offer offset printing for mailer boxes so that your artwork can be as intricate and detailed as desired, without compromising on print quality. To help lower emissions, we use vegetable oil-based inks for offset printing at Sourceful. The carbon footprint of these inks is on average 20-30% lower than solvent-based inks*.

Key benefits:

• Cost-effective when used for high volume print runs.
• Can be used on flexible materials, such as paper, box dividers, carton board.
• Ideal for complex designs, gradients, bright colours, smaller text and photography.
• Multiple single colours and full colour CMYK printing options.
• Colours can be matched to Pantone and GCMI colours.
• Available with a variety of finishes such as gloss or spot varnishes.

Drawbacks:

• Can only be used on flexible, thinner materials, like paper and paperboard.
• Only available with oil-based inks. Most of these are solvent-based and have high levels of volatile organise compound (VOC) emissions. At Sourceful, however, we use vegetable-based oil inks.
• Complex set-up, which means costs are higher for small volumes and MOQs are higher.
• More waste is produced during set-up. A manufacturer needs to run a certain number of units through the machine before the print quality reaches the right standard. This increases with the number of colours. For a one-colour, single-side print job, on average, 80 sheets are wasted for offset printing, whilst for flexo, the number of units wasted drops to 35**.

*By comparing the ink specifications from our suppliers we found that on average, 1 kilo of solvent-based ink has a 20-30% higher carbon footprint than 1 kilo of vegetable-based inks.

** The waste to set up offset printers represents between 7-60% (depending on the process and box size) of the total impact for a MOQ of 500 units. Whereas for flexo printers, the set up waste represents 4% of the total impact for a MOQ of units.

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Digital printing

Digital printing is one of the most accessible printing options online. It's a direct printing process, which uses digital laser or ink-jet printers to print directly onto your packaging. As there's no mechanical setup needed, digital printing is a cost-effective option for small print runs. It also prints in full colour (CMYK), giving you maximum flexibility with your artwork designs. And because it's all digital, you can easily make last-minute artwork changes.

Whilst digital printing allows you to create high-quality and photorealistic designs, you are likely to find small imperfections. For example, colours may be slightly off or the lining of your artwork may be less refined. And depending on the material used, the ink may be absorbed resulting in more muted colours. For this reason, digital printing works best for lower volume prints, such as stickers, and with designs that keep these potential imperfections in mind.

Key benefits:

• Cost-effective process used for small and large print runs.
• Ideal for vibrant, multi-coloured designs and photorealistic images.
• Full-colour printing available at no extra cost.
• Pantone and GCMI colours can be replicated in CMYK.
• Artwork can easily be amended.
• No printing set-up cost, which means a reduced cost for small volumes.

Drawbacks:

• Colours not exactly matched to Pantone and GCMI colours.
• Print quality can vary depending on the equipment and the material printed on.
• Less significant cost savings for higher volumes compared to flexographic and offset printing.
  
  

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High-quality printing online with Sourceful

Each printing process suits different design requirements. Flexographic printing is great for transit packaging like shipping boxes that use simple, bold designs. Digital printing allows you to print smaller volumes of packaging, quickly. And offset printing is the best choice for packaging that requires detailed, high-quality printing.

If you want to keep your carbon footprint low, flexographic printing performs best for lower volumes of smaller products. And offset printing performs better for larger-sized products*.

At Sourceful, we understand each business has different packaging requirements which is why we've made each of these high-quality printing techniques available online.

We've worked with suppliers to support them in bringing these techniques online. This involved building dynamic pricing formulae ' allowing us to price your packaging at the point of sale. We're the first platform to provide dynamic pricing, live visuals and custom sizing for flexo and offset printed packaging. And this allows us to present costs that we can commit to immediately, without going back and forth on plate fees, print costs and more. Get started today.

*When comparing our offset printed mailer box with our flexo printed shipping box, the data showed that at lower volumes for smaller boxes, flexo performs better than offset, given the high printer setup waste. However when you increase the size of the box, offset starts to look more favourable.

If you want to learn more, please visit our website Custom Desk Calendar Bulk.