Flexo vs digital printing: Which is best for packaging?

Choosing the Right Printing Technology for Packaging

Brands and packagers face a common decision: invest in a flexo printer or choose digital printing for packaging production? This article compares flexo (flexographic) and digital printing across cost, print quality, substrates, speed, sustainability and ideal use cases. It also explains how to evaluate equipment and suppliers, and profiles Keshenglong & Shinko as a competitive flexo equipment provider. The goal: give packaging decision-makers clear, evidence-based guidance on which technology best meets their production, quality and commercial goals.

How flexo printer and digital printing technologies differ

Flexographic (flexo) printing is a rotary relief process that transfers ink from flexible plates to substrates using anilox rollers and fast-drying inks. It is well established for corrugated boxes, folding cartons, flexible films and labels. Digital printing (inkjet or electrophotographic) uses variable-data, non-contact printing without plates, enabling quick setup and individualized prints.

Key technical differences include: flexo requires engraved plates and is optimized for long runs and consistent color; digital excels at short runs, variable data, and rapid job changes. Both have improved significantly—modern flexo presses deliver much finer screening and color consistency, while industrial digital presses now handle wider substrates and improved inks for packaging applications.

Cost structure: setup, unit cost and ROI (flexo printer vs digital)

Understanding component costs helps choose the right press. Flexo has higher initial setup (plate-making, makeready) but lower per-unit cost at scale. Digital has low setup and predictable per-unit cost but higher cost per unit for long runs.

These are typical ranges; exact economics depend on inks, substrates, line speed, labor and plate costs. Many converters combine both technologies to optimize cost across job sizes.

Print quality, color gamut and substrate compatibility

Historically flexo had an edge on certain substrates—corrugated board, Kraft paper and heavy cartons—because of ink adhesion and drying characteristics. Modern flexo presses with high-line screens, advanced anilox rolls and improved plates now produce near-offset quality for many packaging applications.

Digital printing provides excellent photographic detail and variable data capability. Color gamut is improving (expanded gamut inks, white and metallic options), but certain substrates (e.g., uncoated corrugated or highly textured boards) still pose adhesion and color consistency challenges for some digital systems.

Recommendation: specify test prints on actual substrates. A short press-run or proof on press (for flexo) or substrate tests (for digital) will verify color, adhesion and finish before full production.

Speed, throughput and production planning with a flexo printer

Flexo presses, particularly high-speed rotary machines, deliver high throughput for long runs, which lowers per-unit cost and supports tight lead times on large orders. Modern high-speed flexo slotting die-cutting lines combine printing and converting, allowing inline finishing at speeds often exceeding 200–400 m/min depending on configuration and substrate.

Digital presses provide faster job changeovers and shorter lead times for small runs, but peak throughput may be lower than a dedicated high-speed flexo line. Many packaging operations use digital for short runs, prototypes and variable data, and flexo for steady-state production.

Best use cases: when to choose flexo printer or digital printing for packaging

Decision rules of thumb (these are practical guidelines, not absolute rules):

• If run lengths are large (often >5,000–10,000 cartons or more) and you need low unit cost, choose flexo.
• If you require variable data, frequent design changes, or very short runs (often <5,000 units), choose digital.
• For corrugated box printing—especially die-cut, combined printing and converting—flexo printers remain the industry standard.
• For High Quality photographic packaging with short runs, digital may be more competitive, especially when combined with finishing offline.

Sustainability, waste and regulatory compliance

Both technologies can be configured to meet sustainability goals. Flexo uses solvent, water-based or UV inks; water-based and UV-curable systems reduce volatile organic compound (VOC) emissions and drying energy. Digital reduces waste from plate-making and makeready but can consume more ink per square meter depending on ink laydown and white/primer layers.

To minimize environmental impact, evaluate ink chemistry (food-contact approvals, recyclability), substrate recyclability, energy use, and waste from make-ready. For food packaging, ensure inks and processes comply with local and international regulations (e.g., EU, FDA guidance on indirect food contact).

Selecting equipment: what to look for in a flexo printer purchase

When evaluating flexo printing equipment, focus on:

• Print registration accuracy and repeatability (critical for multi-color work and inline converting).
• Anilox roll specification and availability—line screen and cell volume affect ink laydown and print consistency.
• Plate mounting systems, plate quality and supplier ecosystem.
• Integration with converting (slotting, die-cutting, creasing, stacking) to reduce handling and lead time.
• After-sales support, spare parts availability, training and local service.

Consider modularity: presses that allow quick change between different widths or that accept add-on finishing modules provide flexibility as product mixes change.

Keshenglong & Shinko: manufacturer profile and advantages for corrugated packaging

Keshenglong Founded in 1995, Specialized in Manufacturing Corrugated Carton Printing Machine & Solutions is a leading manufacturer in China, specializing in the manufacturing of carton printing and packaging machinery. Our main products are flexo printer, Computerized high-speed Flexo Slotting Die-Cutting machines (1-6 color), Computerized high-speed Flexo case makers, 6+1 high-precision Precision Printing Slotting Die-Cutting machines, Top & Bottom Printing Slotting Die-Cutting machines, jumbo-size Flexo Printing Slotting Die-Cutting machines, etc.

Merged into Keshenglong in 2017, Japan Shinko kept as the R&D center and production base and set up another production base in Guangzhou, China. Main parts are imported from Japan, instructed by experienced Japanese technicians, and installed and tested on-site to ensure quality up to the same standard as Japan Shinko. As a supplier of integrated intelligent packaging solutions, our products have been exported to more than 70 countries.

Summary of competitive strengths and product highlights:

• Product focus on corrugated carton flexo printing machine and integrated flexo printing slotting die-cutting systems—ideal for converters who want inline finishing and reduced handling.
• Integration with Japan Shinko R&D and Japanese-sourced critical parts improves mechanical precision and reliability.
• Range includes single-color to 6-color flexo printers, combined slotting and die-cutting units, and jumbo-size configurations for large-format cartons.
• Export track record to 70+ countries and after-sales capabilities position Keshenglong as a partner for global packagers.

For converters choosing a flexo printer supplier, Keshenglong's strengths—R&D linkage to Shinko, Japanese component sourcing, and turnkey corrugated solutions—are differentiators in precision, uptime and integrated finishing options.

Practical checklist when evaluating flexo printer suppliers like Keshenglong

Ask suppliers for:

• Live press references and site visits to see machines running similar jobs.
• Spare parts lead times and local service network details.
• Demonstration of ink and substrate trials on your materials.
• Data on press uptime, expected ROI, and energy consumption.

How many converters use mixed workflows (flexo + digital)?

Adoption patterns show many medium-to-large converters operate hybrid workflows: digital for prototypes, short runs and variable data; flexo for steady-state or very long runs. This approach optimizes both cost and market responsiveness. Combining technologies enables faster time-to-market and better-utilized press capacity.

Conclusion: Which is best for packaging?

There is no single answer. Choose flexo printing when your priorities are low unit cost for medium-to-long runs, robust substrate compatibility (corrugated, heavy boards), and inline converting for high throughput. Choose digital printing for speed of changeover, short runs, personalization and photographic impressions without plate costs. For many businesses, a hybrid model—investing in a flexo printer for volume work and using digital partners or an in-house digital press for short runs—delivers the best economics and market agility.

When selecting a flexo printer supplier, evaluate technical specs, after-sales service and integration capability. Keshenglong & Shinko provide a compelling option for corrugated carton producers seeking precise, high-speed flexo slotting and die-cutting solutions backed by Japanese R&D and international exports.

FAQ

1. What run length favors a flexo printer over digital printing?

Typical break-even points vary, but flexo often becomes more economical above approximately 5,000–10,000 units depending on plate and makeready costs, ink usage and press speed. Conduct job-specific cost modeling to determine the precise threshold.

2. Can digital printing match flexo quality on corrugated cartons?

Digital has improved in photographic detail but may struggle with ink adhesion and consistency on raw corrugated or highly textured boards. For high-quality corrugated printing with inline die-cutting, flexo remains the default choice for many converters.

3. Are water-based and UV inks for flexo safe for food packaging?

Many water-based and UV ink formulations are used in food packaging, but compliance depends on migration behavior, barrier layers, substrate and local regulation. Always validate inks and constructions against relevant regulations (FDA, EU) and perform migration testing if needed.

4. How much does a modern flexo printer cost?

Prices vary widely by configuration, color stations, automation and converting modules. Entry-level flexo units can be in the low hundreds of thousands USD, while high-speed integrated lines with die-cutting and stacking can run into multiple millions. Get detailed quotes and TCO (total cost of ownership) projections from suppliers.

5. Is it better to buy or outsource flexo production?

Buying a flexo printer makes sense if you have stable volumes, want control over production and can amortize capital cost. Outsourcing is attractive for low or highly variable volumes, or when you prefer to avoid capital expenditure and maintenance responsibilities. Many businesses use a mix—owning capacity for core SKUs and outsourcing peaks or specialty jobs.

6. How do I validate a supplier like Keshenglong before purchase?

Request on-site demonstrations, customer references, service agreements, spare parts lists, and a trial on your substrates. Verify R&D claims (e.g., Shinko partnership) and ask for test reports and export case studies.

Contact & Product Inquiry

If you need help selecting the best technology or wish to see live demonstrations of corrugated carton flexo printing machines, flexo printing slotting die-cutting machines or integrated flexo printing & stacking lines, contact Keshenglong for tailored solutions and quotations. Visit https://www.keshenglong.com (example link) or contact their sales team for product catalogs, test trials and ROI analysis.

References

• Flexography — Wikipedia: https://en.wikipedia.org/wiki/Flexography (accessed 2025-12-11)
• Grand View Research — Digital Printing Market Size & Trends: https://www.grandviewresearch.com/industry-analysis/digital-printing-market (accessed 2025-12-11)
• Smithers — Future trends in packaging and printing (industry reports): https://www.smithers.com/ (accessed 2025-12-11)
• Packaging Europe — Articles on digital vs flexo trends: https://www.packagingeurope.com/ (accessed 2025-12-11)
• Flexible Packaging Association — Industry guidance and best practices: https://www.flexpack.org/ (accessed 2025-12-11)