If you’ve been involved with ordering product labels, you’ve probably realized that the type of printing technology you choose can have a big impact on your budget and the final result. Maybe your business is growing, and you need to scale up production. Or perhaps you’re looking to make your labels stand out with more customization and vibrantet designs. Either way, choosing between digital and flexographic printing options is an important step.
Both methods have their strengths, but which one is right for your needs? Let’s take a closer look at how these technologies compare, so you can make an informed decision that fits your goals.
Digital Printing vs. Flexographic Printing: What’s the Difference?
When it comes to label printing, understanding the differences between digital and flexographic printing can help you make the right choice for your business.
Digital Printing
Digital printing is a modern, plate-free process that works by applying tiny ink droplets or toner directly onto materials like paper, plastic, or foil. Since there are no plates to create, setup is quick and requires minimal effort. This makes digital printing ideal for short runs—when you need a smaller number of labels without the hassle of long setup times. Another key benefit of digital printing is the ability to easily customize designs. If your labels need to feature unique elements like variable data, personalized text, or barcodes that change with each batch, digital printing can handle these changes without slowing down production.
Because of this flexibility, digital printing is perfect for companies that regularly update their label designs or have a diverse range of products with different labeling needs. You can quickly switch designs between prints without the need for new plates or extensive setup, making it a great solution for brands looking to test new designs or offer limited-edition packaging. It also delivers sharp, high-resolution images, ensuring your labels stand out on the shelf with vibrant colors and detailed graphics.
Flexographic Printing
Flexographic printing, on the other hand, uses flexible plates made from rubber or plastic that are wrapped around cylinders. These plates transfer ink onto the material, making the process more traditional but incredibly efficient for high-volume jobs. Flexographic printing shines when you need to produce large quantities of labels. Although it takes longer to set up due to the creation of custom plates, once everything is in place, flexographic printing is very fast and efficient, especially for long, consistent runs.
Another advantage of flexo printing is its ability to work with a wide range of materials. Whether you’re printing on paper, plastic, metallic films, or even flexible packaging, flexo printing can handle it. This versatility makes it a great choice for businesses needing to print on different substrates or for industries that use specialty materials.
However, flexographic printing comes with higher upfront costs due to the plate creation process. But once the plates are made, the cost per label drops significantly as you scale up the number of prints. This makes flexo the go-to option for large-scale production where you can spread out the setup costs over a longer run.
Cost Comparison: Which Is More Affordable?
Cost is always a big factor in choosing a label printing technology. Here’s how digital and flexographic printing stack up:
- Digital printing has low setup costs because no plates are needed. It’s great for small orders and short runs where flexibility is important. If you need to make frequent changes or print variable data (like personalized labels), digital printing saves time and money.
- Flexographic printing, while more expensive to set up due to the need for plates, becomes more cost-effective for large print runs. Once the plates are ready, flexo printing is fast and can handle very large orders at a lower cost per unit than digital printing.
Quality and Customization: Which Produces Better Labels?
Both digital and flexographic printing produce high-quality labels, but each has its strengths.
- Digital printing delivers sharp, high-resolution images and vibrant colors. It’s excellent for detailed designs and offers easy customization. If you need different versions of a label with slight changes (like adding unique barcodes or batch numbers), digital printing is the best choice. The ability to print multiple versions quickly without new plates makes it highly flexible.
- Flexographic printing can also produce high-quality results, especially for simple designs. It works well with a variety of materials, from paper to metallic films. While it may struggle with very fine details compared to digital, flexo printing is a great option for long, consistent runs with minimal changes.
Speed and Flexibility: How Quickly Can I Get My Labels?
If you’re working with tight deadlines or need last-minute changes, speed and flexibility are essential.
- Digital printing offers quick turnaround times because it doesn’t require printing plates. You can have your labels printed and ready to go faster than with flexographic printing. Digital is also more flexible if you frequently change your label designs or need smaller orders on demand.
- Flexographic printing, once the plates are ready, is extremely fast for high-volume jobs. It’s ideal for businesses with large, consistent orders that don’t change frequently. While setup can take longer, the printing process itself is very efficient.
Environmental Impact: Which is Greener?
Sustainability is becoming more important for businesses. If reducing your environmental footprint is a priority, here’s what to consider:
- Digital printing is generally more eco-friendly. Without the need for plates or excessive materials, it produces less waste and uses less energy. This makes it a greener choice for short-run projects or when customization is needed.
- Flexographic printing traditionally creates more waste due to the plates and inks used. However, new advances, like eco-friendly inks and improved plate-making processes, are making flexo printing more sustainable. It’s still better suited for high-volume orders, but it’s becoming greener over time.
Which Printing Technology Is Right for Your Business?
When deciding between digital and flexographic printing, it all comes down to your specific needs:
- Choose digital printing if you need smaller quantities, want to make frequent design changes, or require customized labels (like adding unique barcodes or changing product information regularly). Digital is perfect for businesses that need flexibility and fast turnarounds.
- Go with flexographic printing if you’re handling large, consistent orders. If you print thousands of labels at a time and don’t need frequent changes, flexographic printing will save you money in the long run. It’s great for large-scale production where cost per label is a concern.
Epsen Hillmer Graphics: Your Partner in Label Printing
Whether you choose digital or flexographic printing, find a partner like Epsen Hillmer who has the technology and expertise to meet your needs. We offer both methods, so we can help you find the best solution for your business, no matter your order size or complexity. Our team is here to guide you through the decision-making process and ensure your labels stand out.
Not sure which printing method is the best fit for your product? Download our free eBook to dive deeper into the pros and cons of each print method, and which is best for your product. Inside, you’ll find expert insights, real-world examples, and everything you need to choose the perfect printing solution for your unique needs. Get your copy today and make an informed decision!
