Graphic Design
How to Choose the Right Printing Method for Packaging
We arrange packaging and label printing for businesses of every size. This guide is for owners choosing how to print their packaging. It compares the main printing methods, the factors that decide the choice and the questions to ask a printer. Use it before you request quotes, so you compare the right options.
The main packaging printing methods
Each printing method suits different quantities, materials and budgets. Some are cheaper for short runs, and others become cheaper at volume. The table below compares the methods you are most likely to see. Your printer will recommend the best fit for your job.
| Method | Best suited to | Strengths | Limitations |
|---|---|---|---|
| Digital printing | Short runs, samples and personalised packs | No printing plates, fast set-up, easy changes | Higher cost per unit at large volumes |
| Litho (offset) printing | Medium to large runs of boxes and cartons | High quality and consistent colour | Set-up costs make short runs expensive |
| Flexographic printing | Large runs of labels, bags and flexible packaging | Fast and economical at volume | Plates add cost and time to changes |
| Screen printing | Bold designs on glass, metal, fabric and some plastics | Thick, durable ink on unusual surfaces | Fewer colours and less fine detail |
Many small businesses start with digital printing. It keeps first orders small while the product proves itself. Larger runs can then move to litho or flexo for a lower unit cost.
The factors that decide the method
The right method depends on more than price. Your quantities, materials and design all affect the choice. Some finishes only suit certain methods. Consider these factors.
- Order quantity, now and once sales grow.
- The material, such as card, paper, film, glass or metal.
- The number of colours and whether you need exact brand colours.
- Finishes, such as foil, embossing, matt or gloss.
- How often designs change, such as seasonal versions or new variants.
- Lead times and how quickly you need stock.
Share these details with every printer you approach. Consistent information makes quotes easier to compare. Our design and print service helps you weigh the options.
Questions to ask a packaging printer
A printer's answers show whether they suit your project. Clear, specific answers signal experience with your type of packaging. They also reveal costs that are not obvious at first. Ask these questions.
- Which method do you recommend for my quantity and material, and why?
- What are the set-up costs, and at what quantity does the unit price drop?
- Can you match my brand colours, and how do you check them?
- What file format, bleed and resolution do you need?
- Can you supply a printed proof or sample before the full run?
Get every quote in writing, with set-up and unit costs shown separately. Our guide to custom packaging costs explains the full cost picture.
Printing method checklist
Use this checklist before you choose a printing method. Each item helps you match the method to your product and budget. Revisit it when your order quantities grow.
- Current and future quantities estimated
- Material and finishes decided
- Brand colour requirements noted
- Frequency of design changes considered
- Quotes include set-up and unit costs separately
- Proof or sample requested before the full run
Good to know
Printing method FAQs
What is the cheapest way to print packaging?+
Digital printing is usually cheapest for small quantities because it needs no plates. Litho and flexo become cheaper per unit at larger volumes. The break-even point depends on your design and material. Ask printers to quote several quantities.
What is the difference between litho and digital printing?+
Litho printing uses plates and suits larger runs with consistent, high-quality colour. Digital printing works without plates and suits short runs and frequent changes. Quality from both methods is high for most packaging. Quantity usually decides between them.
Can I print small quantities of custom packaging?+
Yes, digital printing makes small runs practical and affordable. It suits samples, launches and limited editions. Unit costs are higher than at volume. Many businesses start small and move to other methods as sales grow.
Keep this checklist with your printer quotes and artwork files. Share it with anyone who orders packaging for your business. So you can choose a printing method that fits your quantities, budget and brand.
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