Key takeaways
- Offset: best colour quality for medium and large runs.
- Digital: no plates, ideal for short runs and personalisation.
- Flexo: fast and economical for corrugated boxes and labels.
- Screen printing: bold opaque colour on specialty materials.
- Finishes such as foil and spot UV are applied after printing.
Why the printing method matters
Two identical-looking boxes can cost very different amounts depending on how they are printed. Each method has different setup costs, speeds and quality levels. Choosing the right one for your quantity and material can significantly lower your cost per box or noticeably improve how your packaging looks.
Methods at a glance
A side-by-side comparison:
| Method | Best for | Typical run size | Quality |
|---|---|---|---|
| Offset lithography | Folding cartons, rigid box wraps | 1,000+ | Excellent |
| Digital | Samples, short runs, variable data | 1 to a few thousand | Very good |
| Flexographic | Corrugated boxes, labels | Large | Good to very good |
| Screen printing | Bold logos on kraft, wood, specialty boards | Small to medium | Good, very opaque |
| Litho-lamination | High-graphic corrugated boxes and displays | Medium to large | Excellent |
Offset printing
Offset uses a metal plate for each ink colour. Ink is transferred from the plate to a rubber blanket and then onto the board. Making plates costs time and money, but once the press is running it is fast and consistent, with excellent colour and fine detail. That is why most retail cartons for cosmetics, food and pharma are printed offset.
Digital printing
Digital presses print straight from a file using toner or inkjet, with no plates. Setup is quick and cheap, making digital ideal for prototypes, short runs, multiple designs and personalised packaging with names or codes. The cost per box is higher than offset at large quantities, but quality is now very good.
Flexographic printing
Flexo uses flexible photopolymer plates and fast-drying inks and can print directly onto corrugated board. It is efficient for long runs of shipping boxes and labels. Simple graphics work best, though high-definition flexo has greatly improved quality.
Screen printing
Screen printing pushes thick ink through a mesh stencil, giving bold, opaque colours. It is useful for one- or two-colour logos on kraft boxes, wooden boxes and textured materials where other methods struggle.
Premium finishes
After printing, finishes can transform a box: lamination (gloss, matte or soft-touch) protects and changes the feel; foil stamping adds metallic shine; embossing and debossing add depth; spot UV adds glossy highlights. One or two finishes are usually enough for a premium look.
How to choose
Under about 500 units in full colour, choose digital. For 1,000 or more folding cartons, choose offset. For large runs of corrugated boxes, choose flexo or litho-lamination. For bold logos on wood or textured boards, choose screen printing. We recommend the best method with every quote.
Frequently asked questions
What is the best printing method for boxes?
Offset for quality at volume; digital for short runs.
What is the best method for short packaging runs?
Digital printing, because it needs no plates.
Can you screen print on cardboard?
Yes, especially simple one- or two-colour logos.
What is litho-lamination?
Printing a sheet offset and laminating it onto corrugated board.