In the print and packaging industry, there are generally two types of printing that can be used to produce custom labels, packaging, and other commercial items: flexographic printing and digital printing.
Having first arrived on the scene in the 1990s, digital printing is relatively new compared to flexographic printing. And while digital printing has grown rapidly in both usage and capability, with projected market size of USD 27 billion by 2026, it still pales in comparison to its older flexographic counterpart. The flexographic printing market was valued at a far greater USD 107.42 billion in 2020 and is expected to reach USD 124.61 billion by 2026.
As businesses strive to innovate and prepare for an uncertain future, many are taking stock of their existing tools and processes to see which can be revisited and updated. For print businesses with a long history of using flexographic printing presses, this means assessing whether their existing hardware should be replaced with newer, digital printing presses.
Let’s explore the benefits and drawbacks of each to help you determine which is better suited for your print business.
Flexography
Flexographic printing involves mounting flexible plates to cylinders that continuously roll ink prints onto the substrate material. These machines can print extremely quickly and for extended periods of time, making this technique ideal for high-volume prints of designs with low variation, such as product labels.
Another key benefit of flexographic printing is the versatility it offers, in terms of the different types of substrates that can be printed on, as well as finishes such as lamination and foils.
The primary drawback of flexographic printing is that it takes time to change printing plates whenever a new design is needed. In an industrial operation, whenever a machine is not printing, it’s not making money. Any job where a high number of SKUs need labels printed will need a suitably high number of flexographic printing machines in order to avoid costly inefficiencies.
Digital printing
Digital printing involves printing an image directly from a computer system onto a substrate by means of an inkjet or laser. Digital printing is ideal for smaller-scale operations with high variation in the print designs, as the design file can be edited digitally without significant disruptions to the hardware and equipment.
Another key benefit of digital printing is its colour accuracy, as its able to produce 97% of Pantone colours. This makes it well-suited for any project where bright, vivid, and consistent colours are required.
A key drawback of digital printing compared to flexographic printing is its limited options for substrates and finishes, as well as its lower volume turnout.
Hybrid printing: why not both?
As highlighted in the above sections, both digital and flexo printing have a lot to offer printing businesses. Thankfully, these printing methods are not mutually exclusive. They can be used together as a hybrid solution that offers the best of both worlds.
Hybrid printing empowers printing businesses to offer their customers the full spectrum of printing services. If a large FMCG client requires a high volume of bottle labels, flexographic printing can be used on the project. If a short-run project arises that needs more control and accuracy across prints, such as brochures or flyers, then digital printers would be the better choice.
Digital and flexographic printing are complementary technologies that can position your print businesses for future success.
At tesa, we’re committed to helping print businesses future-proof their operations with more sustainable, efficient processes. That’s why we’ve written a detailed guide to help you do just that. Click here to get your copy of Future Proof Your Print Business.
