Digital vs Flexo Printing: Which Is Right for Your Packaging Business in 2025?

In the modern packaging industry, businesses have a range of printing technologies to choose from. Among them, digital printing and flexographic (flexo) printing are two of the most widely used methods. Each offers distinct advantages depending on production needs, order volume, and design complexity. Whether you're producing large runs of corrugated cartons or small batches of custom labels, understanding the differences between these two approaches can help you make a more informed decision. This blog explores the strengths, limitations, and ideal use cases of digital and flexo printing to help you choose the right solution for your packaging business.

What Is Flexo Printing?

Definition & Process
Flexographic printing uses a flexible photopolymer plate mounted on a rotating cylinder. Ink transfers from the plate to a wide variety of substrates like corrugated packaging, plastic films and paper labels at high speeds.

Pros of Flexo

• Low unit cost at scale: As production volume increases, cost per carton drops significantly.

• High-speed production: Ideal for mass runs exceeding 10,000 units.

• Material versatility: Can print on corrugated boxes, film, foil, and paper.

• Durability & consistency: Excellent ink laydown for rugged shipping cartons.

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Cons of Flexo

• Plate-making required: Prepress preparation adds time and cost.

• Limited variable data: Not suitable for QR codes or serialized printing.

• Color flexibility: Adjusting spot colors can be time-consuming.

What Is Digital Printing?

Definition & Process
Digital printing applies ink or toner directly to the substrate—no plates needed. Popular methods include inkjet and electrophotographic processes.

Pros of Digital

• Quick setup & turnaround: Ideal for short run printing packaging and rush orders.

• Variable Data Printing (VDP): Easily print unique barcodes, QR codes, and personalization.

• High-resolution output: Superb color accuracy for premium digital label printing.

• Minimal waste: No plate waste, reduces material usage.

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Cons of Digital

• Higher unit cost for large volumes: Not as cost-effective for runs over 5,000 units.

• Material limitations: Some substrates require special coatings or pretreatment.

• Speed constraints: Print speeds lower than dedicated flexo presses.

How to Choose the Best Printing Method

Decision Factors

• Annual Volume: Runs <3,000 units favor digital; >10,000 favor flexo.

• Variable Data Needs: If you need QR codes or serialized labels, choose digital.

• Brand Aesthetics: For vibrant, photo-quality packaging, digital printing excels.

• Cost Analysis: Calculate break-even point—often around 5,000–8,000 units.

Keshenglong: A Reliable Partner for Packaging Printing Solutions

As a leading packaging equipment manufacturer, Keshenglong combines Japanese Shinko technology with Chinese manufacturing efficiency to deliver flexo printing machine solutions.

Key Advantages

1. Integrated Production Line: From flexo press and die-cutting to folder-gluer and automatic stacking.

2. Global Support Network: 24/7 technical service, spare parts in 90+ countries.

3. Proven ROI: Clients report up to 30% reduction in per-unit cost on high-volume runs.

4. Compliance & Certifications: ISO9001, CE, and multiple patents ensure top quality.

Ready to optimize your packaging line in 2025?

Send us your packaging requirements and get a tailored equipment proposal from Keshenglong.