Printing Process Technologies - TX: Difference between revisions
From imde.io
(Created page with "<onlyinclude> = Printing Process Technologies for Packaged Goods = == Overview == Printing on packaged goods is essential for branding, regulatory information, and shelf impact. The optimal process depends on substrate, run length, artwork complexity, cost, lead time, and sustainability targets. This page covers technologies commonly used for labels, bottles, cans, flexible films, folding cartons, corrugated packaging, and wraps. == Quick Comparison == {| class="wikita...") |
No edit summary |
||
| Line 1: | Line 1: | ||
= Printing Process Technologies for Packaged Goods = | = Printing Process Technologies for Packaged Goods = | ||
== Overview == | == Overview == | ||
Printing on packaged goods | Printing on packaged goods supports branding, regulation, and shelf impact. The optimal process depends on substrate, run length, artwork complexity, cost, lead time, and sustainability targets. This page covers technologies used for labels, bottles, cans, flexible films, folding cartons, corrugated packaging, and wraps. | ||
== Quick Comparison == | == Quick Comparison == | ||
{| class="wikitable sortable" | {| class="wikitable sortable" | ||
! Technology !! Typical Quality !! Cost Efficiency !! Best Run Length !! Primary Substrates !! Typical Use | |||
|- | |||
| - | | Flexographic (Flexo) || High || Medium || Medium to long || Films, paper, foil, laminates, corrugated || Labels, flexible packaging, shrink sleeves, cartons | ||
| Flexographic (Flexo) | |- | ||
| - | | Rotogravure (Gravure) || Very high || Low for short runs, high for very long runs || Very long || Films, foil, paper with smooth surface || Premium films, decorative laminates, high volume wrappers | ||
| Rotogravure (Gravure) | |- | ||
| - | | Offset Lithography || Very high || Medium || Medium || Paper, paperboard, some coated boards || Folding cartons, paper labels, sleeves | ||
| Offset Lithography | |- | ||
| - | | Digital Printing (Toner or Inkjet on web or sheet) || High || High for short runs, lower for versioned work || Very short to short || Labels, cartons, some films and foils with primers || Personalization, short runs, prototypes | ||
| Digital Printing (Toner or Inkjet on web or sheet) | |- | ||
| - | | Screen Printing (Silkscreen) || Medium to high for spot effects || Low for large areas, good for specialty work || Short || Glass, plastics, metals, coated objects || Direct to bottle decoration, tactile varnish, opaque whites | ||
| Screen Printing (Silkscreen) | |- | ||
| - | | Industrial Direct to Container Inkjet || High || High for short runs, variable data friendly || Very short to short || Bottles, cans, jars, tubes with compatible shapes || Late stage decoration, coding, customization | ||
| Industrial Direct | |- | ||
| - | | Hot Foil or Cold Foil Stamping || Premium finish || Add on cost || n/a || Labels, cartons, sleeves || Metallic accents, holographics, premium branding | ||
| Hot Foil or Cold Foil Stamping | |} | ||
| } | |||
== How to Choose == | == How to Choose == | ||
* '''Substrate''': paper or board versus non porous films, foils, glass, plastics | |||
* '''Substrate''' | * '''Artwork''': solids versus fine text and photos, need for special effects | ||
* '''Artwork''' | * '''Volume''': prototypes to multi million labels | ||
* '''Volume''' | * '''Change frequency''': versioning, market specific SKUs, promotions | ||
* '''Change frequency''' | * '''Sustainability''': water based inks, recyclability, energy use | ||
* '''Sustainability''' | * '''Downstream converting''': laminating, varnishing, die cutting, forming, sterilization | ||
* '''Downstream converting''' | |||
== Flexographic Printing (Flexo) == | == Flexographic Printing (Flexo) == | ||
'''Principle:''' Relief process using flexible photopolymer plates. Ink is metered by an anilox roller and transferred from raised image areas to the substrate. | '''Principle:''' Relief process using flexible photopolymer plates. Ink is metered by an anilox roller and transferred from raised image areas to the substrate. | ||
=== Key Features === | |||
* Wide ink set: water based, solvent based, UV curable | |||
* Wide ink set: water | * Efficient on roll to roll lines with inline finishing | ||
* | * Compatible with porous and non porous substrates | ||
* Compatible with porous and non | |||
=== Advantages === | |||
* Cost effective for medium to long runs | * Cost effective for medium to long runs | ||
* Fast changeovers | * Fast changeovers and good color consistency | ||
* Strong for labels, | * Strong for labels, films, and shrink materials | ||
=== Limitations === | |||
* Photographic detail requires high quality plates and process control | |||
* Photographic detail requires | |||
* Dot gain and plate wear must be managed | * Dot gain and plate wear must be managed | ||
=== Typical Applications === | |||
* Pressure sensitive and wraparound labels | |||
* Pressure | |||
* Flexible packaging films and laminates | * Flexible packaging films and laminates | ||
* Paperboard cartons and corrugated preprint | * Paperboard cartons and corrugated preprint | ||
== Rotogravure Printing (Gravure) == | == Rotogravure Printing (Gravure) == | ||
'''Principle:''' Intaglio process using engraved cells on metal cylinders. Cells carry ink that transfers directly to the substrate. | '''Principle:''' Intaglio process using engraved cells on metal cylinders. Cells carry ink that transfers directly to the substrate. | ||
=== Key Features === | |||
* Stable tone reproduction and ink density | |||
* Cylinders are durable and reusable for repeat jobs | |||
=== Advantages === | |||
* Very high quality for images and gradients | |||
* Best total cost at very large volumes | |||
* | |||
* Best total cost | |||
=== Limitations === | |||
* High cylinder engraving cost and longer prepress time | * High cylinder engraving cost and longer prepress time | ||
* Less flexible when designs change frequently | * Less flexible when designs change frequently | ||
=== Typical Applications === | |||
* Premium flexible packaging and decorative laminates | * Premium flexible packaging and decorative laminates | ||
* High | * High volume wrappers and foils | ||
== Offset Lithographic Printing == | == Offset Lithographic Printing == | ||
'''Principle:''' Planographic process. Image transfers from plate to rubber blanket to substrate, using the oil | '''Principle:''' Planographic process. Image transfers from plate to rubber blanket to substrate, using the oil water repulsion principle. | ||
=== Key Features === | |||
* Suited to sheet or web paper and paperboard | * Suited to sheet or web paper and paperboard | ||
* Excellent fine text, lines, and photographic imagery | * Excellent fine text, lines, and photographic imagery | ||
=== Advantages === | |||
* High quality with tight registration | * High quality with tight registration | ||
* Efficient for medium runs of cartons and labels | * Efficient for medium runs of cartons and labels | ||
=== Limitations === | |||
* Limited on stretchable films without special treatments | * Limited on stretchable films without special treatments | ||
* Less suitable for variable data | * Less suitable for variable data | ||
=== Typical Applications === | |||
* Folding cartons and sleeves | * Folding cartons and sleeves | ||
* Paper labels and inserts | * Paper labels and inserts | ||
== Digital Printing (Toner and Industrial Inkjet on web or sheet) == | == Digital Printing (Toner and Industrial Inkjet on web or sheet) == | ||
'''Principle:''' Plate | '''Principle:''' Plate free, file to press imaging using electrophotography or inkjet. | ||
=== Key Features === | |||
* Supports versioning, serialization, and rapid design changes | * Supports versioning, serialization, and rapid design changes | ||
* Minimal makeready and waste on short runs | * Minimal makeready and waste on short runs | ||
=== Advantages === | |||
* Ideal for personalization and market testing | * Ideal for personalization and market testing | ||
* Fast lead times | * Fast lead times and low startup cost | ||
=== Limitations === | |||
* Higher unit cost at long runs | * Higher unit cost at long runs | ||
* Substrate compatibility may require primers or certified stocks | * Substrate compatibility may require primers or certified stocks | ||
=== Typical Applications === | |||
* Short run and personalized labels and sleeves | |||
* Short | |||
* Prototypes and promotional editions | * Prototypes and promotional editions | ||
* Late | * Late stage customization before packing | ||
== Screen Printing (Silkscreen) == | == Screen Printing (Silkscreen) == | ||
'''Principle:''' Ink forced through a stencil on a mesh screen onto flat or curved items. | '''Principle:''' Ink is forced through a stencil on a mesh screen onto flat or curved items. | ||
* | === Key Features === | ||
* High ink laydown for opacity and tactile effects | |||
* Works on irregular or 3D shapes | * Works on irregular or 3D shapes | ||
=== Advantages === | |||
* Durable graphics, strong whites, braille and tactile varnish | * Durable graphics, strong whites, braille and tactile varnish | ||
* Specialty effects: metallics, textured, glow, spot gloss | * Specialty effects: metallics, textured finishes, glow, spot gloss | ||
=== Limitations === | |||
* Slower than flexo or digital for large areas | * Slower than flexo or digital for large areas | ||
* Each color requires a separate screen | * Each color requires a separate screen | ||
=== Typical Applications === | |||
* Direct decoration on bottles, jars, tubes, and caps | * Direct decoration on bottles, jars, tubes, and caps | ||
* Special | * Special effect label overprints | ||
== Industrial Direct to Container Inkjet == | |||
'''Principle:''' Non contact inkjet heads print directly on 3D objects. Often UV curable for instant curing. | |||
== | === Key Features === | ||
* True late stage printing on formed containers | |||
* True late | |||
* Variable data ready: batch codes, QR, alphanumerics, graphics | * Variable data ready: batch codes, QR, alphanumerics, graphics | ||
=== Advantages === | |||
* No labels required and less inventory of preprinted SKUs | |||
* No labels required | |||
* Excellent for short runs and mass customization | * Excellent for short runs and mass customization | ||
=== Limitations === | |||
* Geometry limits and fixturing requirements | * Geometry limits and fixturing requirements | ||
* Throughput lower than high | * Throughput lower than high speed label application at very large volumes | ||
=== Typical Applications === | |||
* Direct to bottle and can decoration | |||
* Direct | * Short run seasonal or localized packaging | ||
* Short | |||
== Hot Foil and Cold Foil Stamping == | == Hot Foil and Cold Foil Stamping == | ||
'''Principle:''' Metallic or holographic foil is transferred to the substrate using a heated die | '''Principle:''' Metallic or holographic foil is transferred to the substrate using a heated die for hot foil or UV curable adhesive and inline transfer for cold foil. | ||
=== Advantages === | |||
* Premium brand accents, security features, high reflectivity | * Premium brand accents, security features, high reflectivity | ||
* Works inline with flexo or offset | * Works inline with flexo or offset on many lines | ||
=== Limitations === | |||
* Added material and process steps | * Added material and process steps | ||
* Large solid metallic areas may show tooling or lay issues if not controlled | * Large solid metallic areas may show tooling or lay issues if not controlled | ||
=== Typical Applications === | |||
* Premium labels, folding cartons, and seals | * Premium labels, folding cartons, and seals | ||
* Logos, borders, and decorative elements | * Logos, borders, and decorative elements | ||
== Process Integration and Finishing == | == Process Integration and Finishing == | ||
* Varnishing: aqueous, UV, or electron beam for protection and gloss or matte effects | * Varnishing: aqueous, UV, or electron beam for protection and gloss or matte effects | ||
* Laminating: barrier films for food contact or scuff resistance | * Laminating: barrier films for food contact or scuff resistance | ||
* Die | * Die cutting and creasing: labels and cartons | ||
* Embossing and debossing: tactile branding | * Embossing and debossing: tactile branding | ||
* Coding and marking: lasers or small | * Coding and marking: lasers or small character inkjet for dates and batch IDs | ||
== Regulatory and Food | == Regulatory and Food Contact Notes == | ||
* Use low migration inks, coatings, and adhesives where required | |||
* Use low | * Validate set off and odor for sensitive products | ||
* Validate set | |||
* Align with regional regulations and brand policies on recyclability, deinkability, and compostability | * Align with regional regulations and brand policies on recyclability, deinkability, and compostability | ||
== Sustainability Considerations == | == Sustainability Considerations == | ||
* Prefer water based or energy efficient curing where feasible | |||
* Prefer water | |||
* Optimize ink coverage and plate or cylinder reuse | * Optimize ink coverage and plate or cylinder reuse | ||
* Design for recycling: avoid incompatible coatings and pigments on mono | * Design for recycling: avoid incompatible coatings and pigments on mono material packs | ||
* Reduce waste with accurate color management and right | * Reduce waste with accurate color management and right first time proofing | ||
== See Also == | == See Also == | ||
* Color management and proofing for packaging | * Color management and proofing for packaging | ||
* Substrate primers and surface | * Substrate primers and surface* | ||
* | |||
[[Category:Taxonomy]] | |||
Latest revision as of 11:58, 26 October 2025
Printing Process Technologies for Packaged Goods
Overview
Printing on packaged goods supports branding, regulation, and shelf impact. The optimal process depends on substrate, run length, artwork complexity, cost, lead time, and sustainability targets. This page covers technologies used for labels, bottles, cans, flexible films, folding cartons, corrugated packaging, and wraps.
Quick Comparison
| Technology | Typical Quality | Cost Efficiency | Best Run Length | Primary Substrates | Typical Use |
|---|---|---|---|---|---|
| Flexographic (Flexo) | High | Medium | Medium to long | Films, paper, foil, laminates, corrugated | Labels, flexible packaging, shrink sleeves, cartons |
| Rotogravure (Gravure) | Very high | Low for short runs, high for very long runs | Very long | Films, foil, paper with smooth surface | Premium films, decorative laminates, high volume wrappers |
| Offset Lithography | Very high | Medium | Medium | Paper, paperboard, some coated boards | Folding cartons, paper labels, sleeves |
| Digital Printing (Toner or Inkjet on web or sheet) | High | High for short runs, lower for versioned work | Very short to short | Labels, cartons, some films and foils with primers | Personalization, short runs, prototypes |
| Screen Printing (Silkscreen) | Medium to high for spot effects | Low for large areas, good for specialty work | Short | Glass, plastics, metals, coated objects | Direct to bottle decoration, tactile varnish, opaque whites |
| Industrial Direct to Container Inkjet | High | High for short runs, variable data friendly | Very short to short | Bottles, cans, jars, tubes with compatible shapes | Late stage decoration, coding, customization |
| Hot Foil or Cold Foil Stamping | Premium finish | Add on cost | n/a | Labels, cartons, sleeves | Metallic accents, holographics, premium branding |
How to Choose
- Substrate: paper or board versus non porous films, foils, glass, plastics
- Artwork: solids versus fine text and photos, need for special effects
- Volume: prototypes to multi million labels
- Change frequency: versioning, market specific SKUs, promotions
- Sustainability: water based inks, recyclability, energy use
- Downstream converting: laminating, varnishing, die cutting, forming, sterilization
Flexographic Printing (Flexo)
Principle: Relief process using flexible photopolymer plates. Ink is metered by an anilox roller and transferred from raised image areas to the substrate.
Key Features
- Wide ink set: water based, solvent based, UV curable
- Efficient on roll to roll lines with inline finishing
- Compatible with porous and non porous substrates
Advantages
- Cost effective for medium to long runs
- Fast changeovers and good color consistency
- Strong for labels, films, and shrink materials
Limitations
- Photographic detail requires high quality plates and process control
- Dot gain and plate wear must be managed
Typical Applications
- Pressure sensitive and wraparound labels
- Flexible packaging films and laminates
- Paperboard cartons and corrugated preprint
Rotogravure Printing (Gravure)
Principle: Intaglio process using engraved cells on metal cylinders. Cells carry ink that transfers directly to the substrate.
Key Features
- Stable tone reproduction and ink density
- Cylinders are durable and reusable for repeat jobs
Advantages
- Very high quality for images and gradients
- Best total cost at very large volumes
Limitations
- High cylinder engraving cost and longer prepress time
- Less flexible when designs change frequently
Typical Applications
- Premium flexible packaging and decorative laminates
- High volume wrappers and foils
Offset Lithographic Printing
Principle: Planographic process. Image transfers from plate to rubber blanket to substrate, using the oil water repulsion principle.
Key Features
- Suited to sheet or web paper and paperboard
- Excellent fine text, lines, and photographic imagery
Advantages
- High quality with tight registration
- Efficient for medium runs of cartons and labels
Limitations
- Limited on stretchable films without special treatments
- Less suitable for variable data
Typical Applications
- Folding cartons and sleeves
- Paper labels and inserts
Digital Printing (Toner and Industrial Inkjet on web or sheet)
Principle: Plate free, file to press imaging using electrophotography or inkjet.
Key Features
- Supports versioning, serialization, and rapid design changes
- Minimal makeready and waste on short runs
Advantages
- Ideal for personalization and market testing
- Fast lead times and low startup cost
Limitations
- Higher unit cost at long runs
- Substrate compatibility may require primers or certified stocks
Typical Applications
- Short run and personalized labels and sleeves
- Prototypes and promotional editions
- Late stage customization before packing
Screen Printing (Silkscreen)
Principle: Ink is forced through a stencil on a mesh screen onto flat or curved items.
Key Features
- High ink laydown for opacity and tactile effects
- Works on irregular or 3D shapes
Advantages
- Durable graphics, strong whites, braille and tactile varnish
- Specialty effects: metallics, textured finishes, glow, spot gloss
Limitations
- Slower than flexo or digital for large areas
- Each color requires a separate screen
Typical Applications
- Direct decoration on bottles, jars, tubes, and caps
- Special effect label overprints
Industrial Direct to Container Inkjet
Principle: Non contact inkjet heads print directly on 3D objects. Often UV curable for instant curing.
Key Features
- True late stage printing on formed containers
- Variable data ready: batch codes, QR, alphanumerics, graphics
Advantages
- No labels required and less inventory of preprinted SKUs
- Excellent for short runs and mass customization
Limitations
- Geometry limits and fixturing requirements
- Throughput lower than high speed label application at very large volumes
Typical Applications
- Direct to bottle and can decoration
- Short run seasonal or localized packaging
Hot Foil and Cold Foil Stamping
Principle: Metallic or holographic foil is transferred to the substrate using a heated die for hot foil or UV curable adhesive and inline transfer for cold foil.
Advantages
- Premium brand accents, security features, high reflectivity
- Works inline with flexo or offset on many lines
Limitations
- Added material and process steps
- Large solid metallic areas may show tooling or lay issues if not controlled
Typical Applications
- Premium labels, folding cartons, and seals
- Logos, borders, and decorative elements
Process Integration and Finishing
- Varnishing: aqueous, UV, or electron beam for protection and gloss or matte effects
- Laminating: barrier films for food contact or scuff resistance
- Die cutting and creasing: labels and cartons
- Embossing and debossing: tactile branding
- Coding and marking: lasers or small character inkjet for dates and batch IDs
Regulatory and Food Contact Notes
- Use low migration inks, coatings, and adhesives where required
- Validate set off and odor for sensitive products
- Align with regional regulations and brand policies on recyclability, deinkability, and compostability
Sustainability Considerations
- Prefer water based or energy efficient curing where feasible
- Optimize ink coverage and plate or cylinder reuse
- Design for recycling: avoid incompatible coatings and pigments on mono material packs
- Reduce waste with accurate color management and right first time proofing
See Also
- Color management and proofing for packaging
- Substrate primers and surface*
