Guide / Printing / Chapter 4.1
Packaging print methods compared.
Digital, screen, flexo and offset printing each suit different packaging, quantities and designs. Here's how they compare, and how we choose the right one for your box.
The short answer
The print method is usually decided by what you're printing on and how many you need. We digitally print kraft brown and white die-cut boxes from 25 units in 5–10 business days, printing your logo on the top, front and back of the box. Screen printing is used on kraft brown, white and black die-cut boxes, and for white ink, from 250 units. Flexo printing is used on shipping cartons, and offset printing on paperboard product boxes, both from 250 units. Screen, flexo and offset take 10–15 business days from artwork approval. Lead times are longer in peak periods, so check our current lead times.
The four main methods
Digital printing
Artwork is printed straight from the file, with no printing plates or screens to set up. That makes it ideal for small runs and full-colour logos. We use digital printing on kraft brown and white die-cut mailer boxes. Full colour doesn't mean full coverage: our digital print goes on the top, front and back of the box only, at least 20 mm from fold edges, up to 280 mm wide, with no white ink, no side panels and no edge-to-edge or large solid backgrounds. See digital printing.
Screen printing
Ink is pushed through a fine mesh screen, one colour at a time. It gives bold, solid colour and can print white ink on dark boards. We use screen printing on kraft brown, white and black die-cut boxes (black boxes are always screen printed), and it's the method we use for Pantone colour matching. See screen printing.
Flexo printing
A flexible printing plate transfers ink onto corrugated board. It suits logos, text and simple graphics on shipping cartons, and is efficient for larger quantities. See flexo printing.
Offset printing
Ink is transferred from a plate to a rubber blanket, then onto the board. It gives sharp, detailed, full-colour printing and is used on paperboard product boxes, such as cosmetic and skincare cartons. Paperboard boxes can be printed inside and outside. See offset printing.
At a glance
| Method | Used on | Minimum order | Lead time | Best for |
|---|---|---|---|---|
| Digital | Kraft brown and white die-cut boxes (top, front and back) | From 25 units | 5–10 business days (made to order 7–10) | Small runs, full-colour logos |
| Screen | Kraft brown, white and black die-cut boxes, white ink | From 250 units | 10–15 business days | Bold solid colours, Pantone matching |
| Flexo | Shipping cartons | From 250 units | 10–15 business days | Logos and simple graphics on cartons |
| Offset | Paperboard product boxes | From 250 units | 10–15 business days | Detailed full-colour retail boxes |
Finishes that go on top
Some decorations are added after printing. Foil adds a metallic or coloured shine and is available in black, white, gold, silver and rose gold on gift bags and rigid boxes, and on paperboard. Embossing, debossing and spot UV are available on paperboard cosmetic boxes and premium gift bags, on request. Gloss or matt lamination protects printed paperboard and changes how it looks and feels.
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
Digital printing is usually the place to start. From 25 units, you can put your logo on a mailer box without ordering hundreds.
Keep the design simple at first: one logo, placed well, looks professional.
Growing · 100 to 2,499 units
Once you're ordering 250 or more of the same box, other methods may become options. They aren't interchangeable: screen suits die-cut boxes, flexo suits cartons and offset suits paperboard, so a change of method can mean a different box or board. Ask us to compare.
Try this: get quotes at two quantities to see how the cost per unit changes.
Enterprise · 2,500 units and more
At volume, flexo for cartons and offset for paperboard are built for longer runs. Specify the print method, colours and finish, and keep an approved reference, so reorders stay consistent within agreed tolerances.
For brand colours that matter, ask about Pantone matching with screen printing, against a physical reference.
Common mistakes
- 1Choosing a method before a box. The box and board usually decide the method. Choose your packaging first.
- 2Expecting every method to match exactly. The same colour can look different on kraft, white board and paperboard. Check your proof.
- 3Over-designing a small run. Complex designs cost more to set up on some methods. A simple, bold design works across them all.
- 4Reading 'full colour' as 'full coverage'. Digital print covers the top, front and back of the box only, away from folds. For all-over print, ask about offset paperboard.
Print method questions
What's the most affordable way to print a small run of boxes?
Which print method is used for shipping cartons?
Can you print white on black boxes?
What's offset printing used for?
How long does printed packaging take?
From our customers
Frida Las VegasA baby pink, custom printed box that customers keep on their dressing tables.
Read their story →Keep reading
Printed packaging
Not sure which print method you need?
Tell us the box, the quantity and your design. Our Melbourne team will recommend the method and send a digital proof within 1 business day of receiving your artwork.