PackLAB

Cardboard printing techniques

Customers often wonder what the difference is between the three most common forms of packaging printing. This page summarises the pros and cons of each printing technology, while noting that general guidelines may vary depending on machine type, machine age, the selected material to be printed on. Over the years, technology has improved across all these techniques. While the information provided applies to most machines in our industry, it does not encompass everything available on the market.

Printing Technology

Offset Printing

Flexo Printing

Digital Printing (Production)

Image transfer to material

Offset Printing: Indirect

Flexo Printing: Indirect

Digital Printing (Production): Direct

Printing form

Offset Printing: CTP Plate

Flexo Printing: Polymer Cliché

Digital Printing (Production): No printing form required

Suitable print run

Offset Printing: Upwards of 1000 sheets

Flexo Printing: Upwards of 1000 sheets

Digital Printing (Production): Up to 1000 sheets

Suitable print applications

Offset Printing: All types of cardboard packaging, printed materials, magazines, etc.

Flexo Printing: Corrugated cardboard packaging, displays, etc.

Digital Printing (Production): Printed materials, posters, packaging, etc.

Materials printed on

Offset Printing: Solid cardboard, paper

Flexo Printing: Corrugated cardboard, types of foil (plastic, aluminium, etc.)

Digital Printing (Production): Solid cardboard, paper

Print quality

Offset Printing: Highest, sharp

Flexo Printing: Lowest, soft

Digital Printing (Production): Comparable to offset printing (but slightly poorer quality)

Position, accuracy

Offset Printing: Precise (0.5 mm deviation)

Flexo Printing: Poorer (1-2 mm deviation)

Digital Printing (Production): Precise (0.5 mm deviation)

Finishing options with varnishes

Offset Printing: Many possibilities

Flexo Printing: Limited use of varnishes

Digital Printing (Production): Inadequate, mostly without protective coatings

Colour selection

Offset Printing: All colours (CMYK + Pantones)

Flexo Printing: Largest colour selection (CMYK + Pantones)

Digital Printing (Production): Smallest colour selection (CMYK + orange, violet, green) - no Pantone colours

Material thickness

Offset Printing: Up to 1 mm

Flexo Printing: Can be more than 5 mm

Digital Printing (Production): Up to 0.7 mm

Initial costs, preparation costs

Offset Printing: Slightly lower than flexo printing

Flexo Printing: Highest

Digital Printing (Production): Lowest

Price comparison

Offset Printing: Slightly more expensive than flexo (plate changes required for certain quantities)

Flexo Printing: Cheapest for larger quantities (faster, clichés have a longer lifespan)

Digital Printing (Production): For larger quantities, considerably more expensive than offset and flexo printing

Cardboard printing techniques

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