Flexo vs Digital Printing: Which is best for your brand packaging?
Navigating the world of printing doesn’t have tobe scary. Ultimately, the right printing method for your brand is the one thatbest fits all your needs—so let’s break it down.
What is Flexographic Printing?
Flexo printing is a surface printing technique that uses flexible rubber or polymer plates mounted on rotating cylinders. Ink is transferred from the ink reservoir via an Anilox roll onto the plate cylinder, where it is pressed against the printing substrate. Think of is as a giant rubber stamp.
What is Digital Printing?
Digital printing eliminates the need for plates by using digital files to print directly onto the substrate. It employs techniques suchas electrographic, inkjet, or laser printing to apply ink or toner. Think of it as a fancy office printer.
Now, let’s compare the
key determining factors for each:
Flexo Printing
1. Setup Time & Cost
High initial setup costs due to plate creation, but very cost-effective for large runs as the per-unit cost decreases significantly with volume. Although Flexo presses run fast, the prepress and plate creation with each color stations takes some time.
2. Image Quality
Ideal for bold, simple designs with large areas of solid color, but less suited for fine details. However, some printers employ advanced plate-making techniques that deliver higher-quality images.
3. Ink
Accommodates a wide variety of inks for process, extended gamut, and Pantone colors. This includes water-based, solvent-based, and UV inks. Embellishments are also an option as Flexo can accommodate in-line processes.
4. Run Length
Best suited for long print runs where the setup and plate costs can be distributed over a larger quantity. Although the set-up time is longer than digital, the printing speed is much faster.
5. Substrate Compatibility
Often used for flexible packaging, but not limited to ridged packaging as it utilizes a variety of substrates including film, paper, paperboard, corrugated, foil, and plastics. It prints on both porous and non-porous surfaces.
In Summary: Flexo Printing is fast and consistent on large-volume printing, but setup costs are high. Not suited for frequent changes. Flexo printing presses offer narrow to wide webs to accommodate many different substrate widths.
Digital Printing
1. Setup Time & Cost
Minimal setup costs and time since there is no need for plate creation. It is more cost-effective for low-volume, short print runs, but not for larger scale.
2. Image Quality
Consistently offers sharp, high-quality, detailed images.
3. Ink
Limited to process colors and extended gamut. Certain Pantone color matches may not be possible, although the color is usually similar. Some digital printing inks may fade more quickly than Flexo inksin direct sunlight.
4. Run Length
Ideal for short to medium runs or jobs requiring frequent changes. This is great for seasonal or limited-edition packages.
5. Substrate Compatibility
Gaining in versatility as the technology for digital printing expands across film, paper, paperboard, fabric, aluminum/metal, and plastics, you name it!
In Summary: Digital Printing excels with small runs and customization.It cuts out the need for plates and offers quick turnaround times.
At HBX Branding, we’ve collaborated extensively with Flexo and Digital printers to ensure your product looks and feels its best on the shelf. Our production team supports you throughout the process, from pre-production calls with separators and printers to drawdown evaluations and both soft and hard proof approvals. We also provide on-site press supervision to ensure your design intentions are met and colors are standardized for consistent future print runs.
Stephanie Doyle
