What are the advantages of digitally printed flexible packaging?


As per statistics, in 2019, the flexible packaging industry was valued at $221.7 billion and is forecasted to be worth $278.95 billion by 2025. With a trendy and tech-friendly digital printing process, you can be a part of this business’s success. Want to know how?

Look no further! Go through this article: digitally printed flexible packaging and get the success of your flexible packaging business. Without further ado, let’s get started together!

What is Digitally Printed Flexible Packaging? 

Digital printing in flexible packaging refers to the process of transferring a digital file to a printer. After that, the image file is used directly for the packaging materials. Unlike traditional print methods, there is no need for individual plates.  

Also, it offers versatile solutions for small to large-sized businesses for promotional purposes. Apart from its high-quality graphics, the printing offers modern technology that suits your business needs. 

Curious to explore different types of printing process for flexible packaging? Without any talk, let’s get started!

What is the Best Type of Custom Printed Flexible Packaging?

The most vital part of a flexible packaging printing business is acknowledging printing methods, etc. All these factors ensure high-quality product designs that enhance customer experience, boost your business, and increase sales. 

However, when it comes to investing in printing methods, flexography may be the first option you may choose. But in this modern tech era, there are several different options, including:

1. Flexography (Flexo Printing)

Flexography or flexo is a flexible printing process that uses flexible relief plates (rubber or plastic). A high-quality and rapid printing method is used in the commercial industry and labeling. 

2. Custom Digital Printing (Ink-Jet Based Printing Method)

Digital flexible packaging printing is an ink-jet-based printing method. This process applies graphics and branding elements directly on the pouches or plastic substrates. For printing, a digital printer is used to process computer files. 

3. Rotogravure (Engraves Graphics)

Another printing method is Rotogravure or Gravure. This method engraves graphics onto a plate, form, or other surfaces before applying them to the final package formats. Here, an image carrier is used to ensure its graphics quality after transferring. 

4. Lithography (Graphic Made from Oil)

The method uses a lithography plate, and graphics are made from oil. The graphics are drawn on the top of the lithographic plate. After that, the plate is treated with acid to ensure the printing quality. 

After covering several printing methods, it’s time to understand how all these processes are applied to flexible packaging materials. Why delay? Scroll down to the next section!

How Does Digital Printing Work with Flexible Packaging?

As per statistics, in 2022, the Global digital printing packaging estimates that it is valued at $17,760.7 million. Also, forecast to grow at a CAGR of 5.1% from 2022 to 2032 and is valued at around $29,206.9 million. Sounds encouraging.

Let’s acknowledge how printing methods on custom packaging works below:

Flexo Label Printing Method

It starts with imaging your design onto a printing plate. And the plate is prepared for each color as per product packaging design. After that, these plates are set up on the printing press. On a flexo press, there are a series of colored rollers, and each roller prints one color. 

Rotogravure Printing Method

A gravure printing process uses laser-etched cylinders instead of a printing plate. Each cylinder carried different colors for the design. However, the printing cylinder carries ink to the web. An impression cylinder also ensures good print and repeats colors based on the packaging design.

Digital Printing Method 

It uses rapidly transferred electronic signatures to the imaging plate. This printing doesn’t require printing plates or cylinders for printing images to flexible pouches. Then the images are transferred to an imaging device, and each ink color is installed in a specified order.

You might wonder which method suits your business or digital printing pouches for packaging foods. Scroll down to the next section to get the answer!

Gravure vs Flexo vs Digital Printing: Which Printed Suits You?

From manufacturers to packaging suppliers, deciding which printing method suits their project’s needs is crucial. Gravure vs. flexo vs. digital printing: the selection depends on some factors, including:

  • Packaging materials,
  • Production costs,
  • Consumer demands & needs,
  • Design & high-quality graphics,
  • Textual elements and other business-oriented issues.

In the hope of helping your business and boosting your sales, we highlight some key aspects below. Let’s get started!

Gravure Printing 

The printing method is designed for repeatability and long-run production purposes. Also, you achieve an excellent half-tone and vignette reproduction. Eager to explore: What makes the Gravure printing process right for your business? Let’s take a closer below:


  • Suit perfectly the product line that requires no significant design changes. 
  • Offer repeatability and high speed to meet the production capacity.
  • Offer quality images for packaging.
  • Allow more than 4 colors compared to flexography.
  • Provide a cost-friendly solution; because you don’t need to spend more money on another printing cylinder.


  • Not suitable and profitable option for small-scale productions. 

Flexo Printing

Flexography is ideal for printing both large areas of colors with in-depth details. It is popular for its versatile options and smooth printing platform for labels and packaging. Let’s take a closer look at some core factors of this printing method.


  • Offer versatile printing, like metallic films, paper, pouches, plastic, etc. 
  • Provide a wide variety of colors and HD printing. 
  • Quick-inks provide food packaging printing safety and boost production speed.
  • Ideal for bulk production.
  • Less expensive and low maintenance is required than rotogravure.


  • Offer a lower quality than the digital option.
  • Suitable for using right away packaging. 

Digital Printing

Unlike traditional print plates, digital printing is one of the fastest-developingprinting methods in the flexible industry. It is the best process for vibrant color, eye-catchy graphics, crisp product details, and high-resolution images. Let’s look at some key factors of digitally printed packaging below:


  • Minimal setup costs require investing in an inkjet printer. 
  • Reduce food wastes.
  • It offers high-quality results and unlimited print customizations on several pouches compared to other processes.
  • Offer the fastest turnaround time.
  • Support SKU proliferation and suitable for ready-to-pack products.


  • Costs higher than other printing processes.

Note: The MOQ of digital printing is very low. For example, it can be 200pcs/SKU. But if the quantity of each design is very low, like 200pcs/SKU with several designs and colors for each, it offers cost-effective options for multiple SKUs.

8 Benefits Why Digital Print Flexible Packaging is Important?

Right product pouches or bags design, supplier, and production process; all of these factors ensure the brand’s success. If you start a new business or have an established one, you need to focus on informational and eye-catchy packaging. 

And whatever your company size is, digitally printed flexible packaging offers you several benefits over conventional printing methods like offset printing. Want to explore why? Let’s go through several advantages below:

1. Improve Your Packaging Design

From minor to major updates before the final product launch, digital method offers versatile and flexible printing solutions. Also, you don’t need to change the whole package design for minor changes like the brand logo, QR codes, etc. Also, it provides other package formats and ensure digital consumer engagement. 

2. No Plates with Digital Printing

From seasonal and promotional packaging to small businesses can take advantage of this printing process. Because no printing plates are required for printing, brands can print multiple SKUs or combine multiple SKUs into one order or digital print. All these factors ensure even more sustainable benefits of your business.

3. Digital Printing for Flexible Packaging

From stand up pouches to quad seals and other transparent or food pouches, digital process offers durability and brand owners authenticity. Also, this printing process gives you a trendy outlook on your products. 

4. Allow Personalized Packaging Options 

Digital printing can be applied to flexible and rigid packaging films and offer personalization options. From taglines to call-to-actions, product shelf life, logos, and layouts for target markets, acknowledge campaigns and can add other features in one bag. 

5. Offering High Value for Low Cost Pricing

If you want to digital print as per your production requirements, you can do it with digital print technology. If you need a small number of copies for your product, digital printing can offer you quick solutions with reasonable pricing.

6. On Demand Fast Delivery

Digital printing on flexible pouches adds bright, vibrant, and precise graphics within an estimated time. Also, for its quick printing method, it allows speedy and flexible delivery solutions. That’s why it has become more popular in the ready-to-eat society.

7. Time Reduce Color Matching Printing

Always ensure high-resolution and quality graphics, texts, brand logos, and other product information. And all these features require less production time compared to traditional printing methods. Custom printing ensures quality materials and sustainable packaging to fulfill consumers’ demands with quality products. 

8. More Eco-Friendly Product

Unlike traditional printing, custom flexible packaging uses fewer natural resources and reduces manufacturing and transporting pollution. That means it produces fewer emissions of CO2 in nature. The product packaging printing industry reduces inventory and food waste by extending shelf life.


Now at the end of this article: digitally printed flexible packaging, you might get enough resources about the high-quality printing processes and which suits your businesses market demand. In this competitive marketplace, always remember to stay up to date and create digital consumer engagement by maintaining product quality. 0

Why are you waiting for? It’s time to scale up your business and achieve your goal.


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