Guide / Artwork & design / Chapter 5.6
Designing for small vs large print runs.
The best packaging design depends on how many you're printing. Here's how quantity changes the print method, the cost per unit and the design choices that make sense.
The short answer
For small runs, digital printing puts full-colour logos on kraft brown and white boxes from just 25 units, with a lead time of 5–10 business days. For larger runs from 250 units, screen, flexo and offset printing can bring the cost per unit down, with a lead time of 10–15 business days. Each method suits particular packaging, so moving to a larger run can mean a different box, board or artwork, not just a bigger order. Screen and flexo printing often suit bold designs in fewer colours, while offset printing suits detailed, full-colour artwork on paperboard. Design for the method you'll actually use.
How quantity changes the method
Each print method has a different set-up. Screen, flexo and offset printing involve preparing screens or plates before printing starts. That set-up is spread across the run, which is why these methods suit larger quantities. Digital printing prints straight from the file, with no plates, which is why it works for small runs.
Here's how we print each type of packaging:
- Kraft brown and white die-cut boxes: digital printing from 25 units, on the top, front and back only, 20mm from fold edges, with no white ink or edge-to-edge print.
- Kraft brown, white and black die-cut boxes: screen printing from 250 units, including white ink. Black boxes are always screen printed.
- Shipping cartons: flexo printing from 250 units.
- Paperboard boxes: offset printing from 250 units.
Small run vs large run
| Small runs | Large runs | |
|---|---|---|
| Typical method | Digital | Screen, flexo or offset |
| Minimum | From 25 units | From 250 units |
| Lead time | 5–10 business days | 10–15 business days |
| Design freedom | Full-colour logos on the top, front and back, many variations | Best with a set number of colours, or full-coverage full colour on paperboard |
| Cost per unit | Higher, but a low total spend | Lower as quantity grows |
| Best for | Launches, testing, seasonal and limited editions | Established products and steady volumes |
Design choices that work at each size
Designing for a small run
Digital printing handles full-colour logos and detail, so you can use different designs for different products without extra set-up. Keep within its limits: top, front and back only, 20mm from fold edges, no white ink, and no edge-to-edge print or large solid backgrounds. It's ideal for seasonal packaging and limited editions.
Designing for a large run
For screen and flexo printing, a design built on a small number of solid colours prints cleanly and keeps costs down. Bold logos and simple layouts work well on kraft and carton board. Screen printing can be matched to Pantone colours. Offset printing on paperboard handles detailed full-colour artwork, which suits retail and cosmetic packaging.
Designing for both
Many brands use one simple design that works in a single colour, then add detail where the print method allows. A strong one-colour version of your logo is the most useful packaging asset you can have.
What it means for you
The same question, answered for where your business is today.
Choose your stage at the top of the page to open the advice for you.
Start-up · under 100 units
Use digital printing to get a professional printed box from 25 units. Keep the design simple so it can adapt if you move to other print methods later, which may also mean a different box or board.
Make a one-colour version of your logo now. You'll use it on stickers, tape and future print runs.
Growing · 100 to 2,499 units
As quantities grow past 250 of the same box, ask which other methods suit that box: screen for die-cut boxes, flexo for cartons, offset for paperboard. The design or the packaging itself might need to change.
Try this: ask for quotes at two quantities to see where the cost per unit drops.
Enterprise · 2,500 units and more
Design for the long-run method from the start. Lock your colours, specify them in your packaging specification and keep artwork consistent across every run.
Changing colours or artwork between runs adds set-up. Plan changes in advance.
Common mistakes
- 1Designing before choosing the method. A detailed, many-colour design can be costly or impossible on some methods. Pick the method first.
- 2Too many colours on a long run. Each extra colour can add set-up. Fewer colours often look bolder too.
- 3Fine detail on kraft board. Thin lines and small text soften on textured board. Keep it bold.
- 4Assuming a digital test proves a later run. A small digital run tests the design and market, but a screen, flexo or offset version may look different. Check its proof and, where available, a sample.
Print run questions
What's the minimum order for printed packaging?
Why is the cost per unit lower on bigger runs?
Can I print full colour on a small run?
What design works best for flexo printing?
How long do printed runs take?
Keep reading
Print at any size
Not sure which print run suits you?
Tell us your quantities and send your design. Our Melbourne team will recommend the print method and quote at more than one quantity if it helps.