Printing Process Technologies - TX

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*