Flexo, digital or litho: how to print custom boxes
How a box is printed affects its price more than almost anything else. Each method has a sweet spot, and picking the right one can save a lot.
Flexo
Flexographic printing uses flexible rubber plates and prints directly onto corrugated board. It is the cheapest way to print one to four solid colours, like a logo and handling marks on a shipping box. Plates are a one time cost, so flexo gets cheaper per box as runs get longer.
Digital
Digital printing needs no plates at all. It prints full colour straight from the file, which makes short runs, test batches and many different designs affordable. The unit price is higher than flexo on long runs, but with no setup costs it often wins below a few thousand boxes.
Litho laminated
A sheet is printed on an offset press (the same quality as a magazine) and then laminated onto corrugated board. It gives the richest colour and finest detail on corrugated, and it suits large runs of retail and display packaging.
Offset for folding cartons
Paperboard cartons are usually printed offset, with CMYK plus Pantone spot colours and finishes added inline. Digital is used for short carton runs.
The quick rule
- One or two colours, plain shipping box: flexo.
- Full colour, short run or many designs: digital.
- Full colour, big run, top quality: litho laminated or offset.
We price the methods that make sense for your quantity, with plates and dies included, so you can compare the real totals.
Ready for a price? Send us your box size and quantity and we will reply with options and a production date.
