Printing Process Technologies - TX

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

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| High | | Medium | | Medium to long | | Films, paper, foil, laminates, corrugated | | Labels, flexible packaging, shrink sleeves, cartons |

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| 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 |

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| Very high | | Medium | | Medium | | Paper, paperboard, some coated boards | | Folding cartons, paper labels, sleeves |

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| 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 |

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| 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 |

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| High | | High for short runs, variable data friendly | | Very short to short | | Bottles, cans, jars, tubes (compatible shapes) | | Late-stage decoration, coding, customization |

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| Premium finish | | Add-on cost | | Any | | Labels, cartons, sleeves | | Metallic accents, holographics, premium branding |

| | | | | | | | | | How to Choose Substrate - paper or board vs non-porous films, foils, glass, plastics Artwork - solids vs fine text and photos, need for special effects Volume - from 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 Runs efficiently 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, good color consistency Strong for labels, filmic wraps, and shrink materials Limitations Photographic detail requires HD 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 Very stable tone reproduction and ink density Cylinders are durable and reusable across repeat jobs Advantages Exceptional quality for images and gradients Best total cost of ownership 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, 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 forced through a stencil on a mesh screen onto flat or curved items. Key Features Very 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, 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, reduces inventory of preprinted SKUs Excellent for short runs and mass customization Limitations Geometry limits and fixturing requirements Throughput lower than high-speed label application on 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 (hot foil) or UV-curable adhesive and inline transfer (cold foil). Advantages Premium brand accents, security features, high reflectivity Works inline with flexo or offset in 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 Common inline or nearline steps: 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 when 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 treatments Packaging compliance for food and cosmetics <<Category:Taxonomoy>>