Choosing Digital vs. Plate Printing for Flexible Packaging

Which Printing Option Makes Sense for Your Order?

When it comes to custom printed flexible packaging, two common methods dominate the process: digital printing and plate printing (also called rotogravure printing). Both techniques have their place in packaging production, but understanding the differences and knowing when to choose one over the other is essential for making the best decision for your brand. Your choice will affect everything from pricing and turnaround time to print quality and material compatibility.

To help you navigate this decision, we’ll break down the basics of each printing method, their advantages, and the factors you should consider when choosing the right approach for your business.

Understanding Digital Printing

Digital printing is an increasingly popular method for custom packaging, especially among small to medium-sized brands. With this process, designs are printed directly onto the packaging material from a digital file, such as a PDF or an AI file. There are no physical printing plates involved, which means there are fewer barriers to entry when it comes to setup time and costs.

One of the biggest advantages of digital printing is its flexibility. If you’re launching a new product or your designs are subject to frequent changes, whether it’s because of a changing logo, seasonal packaging, or evolving marketing campaigns, digital printing allows for quick updates. You can make revisions to the design without worrying about creating new plates or adding extra costs to the process.

The setup is also much faster with digital printing compared to plate printing, which means your lead time is shorter. If you're in a time crunch or have a tight deadline for a product launch or promotional event, digital printing is often the best option. You won’t need to wait for plates to be created or go through an extensive setup process.

Digital printing is ideal for smaller runs, typically under 5,000 units per design. Since digital printing doesn’t require plates, there are no upfront charges associated with creating custom plates, which is a significant cost-saving for brands that don’t need large quantities. However, the trade-off is that the cost per unit tends to be higher for larger orders. This means that as your order volume increases, digital printing may become less cost-efficient.

Another factor to consider is print quality. While digital printing can produce sharp, detailed designs, it may not always achieve the same level of color consistency and richness as plate printing. The technology used in digital printing is improving, but if you’re looking for fine details or specialty finishes like metallics or spot gloss, digital printing may not always provide the same high-quality results as plate printing.

Understanding Plate (Rotogravure) Printing

Plate printing, specifically rotogravure printing, is a more traditional and established method used for high-volume production. This method uses engraved cylinders (or plates) to transfer ink onto the packaging material. The design is etched into the plates, and as the material passes through the printing press, ink is transferred with extreme precision.

One of the biggest benefits of plate printing is its efficiency at scale. While the initial setup for plate printing can be costly due to the need for custom plates, the cost per unit becomes much lower as you produce larger quantities. Plate printing is best suited for runs of 5,000 to 50,000 units or more, making it the go-to option for established brands that need large, consistent volumes.

Another significant advantage of plate printing is the superior print quality. The engraving process allows for precise and vibrant color reproduction, ensuring that designs look sharp and detailed on a variety of materials. Plate printing can also accommodate specialty effects, such as metallic finishes, high gloss, matte coatings, and complex color matching, which are particularly important for brands that want to achieve a premium look.

Unlike digital printing, which is often limited in terms of material choices, plate printing can be used on a wider range of films and substrates. This flexibility allows for the production of high-performance packaging, whether you’re looking for barrier films for coffee or specialized coatings for products like cosmetics or premium food.

However, plate printing comes with certain trade-offs. The most obvious is the upfront cost. Creating custom plates can be expensive, and if your artwork changes frequently, you’ll incur additional costs for new plates. Plate printing also requires a longer lead time compared to digital, as the setup process is more involved. Additionally, plate printing is less flexible than digital printing in terms of design changes, so it’s best for brands with stable, unchanging artwork.

Key Considerations When Choosing Your Printing Method

Order Size:
Perhaps the most important factor in deciding between digital and plate printing is your order size. If you need a smaller quantity, digital printing is the more cost-effective choice. Once you cross the threshold of 5,000 units, plate printing generally becomes more economical due to the lower cost per unit at higher volumes. For very large runs, plate printing is the clear winner.

Design Flexibility:
If your design is likely to change—whether due to seasonal updates, new flavors, or special promotions—digital printing gives you the freedom to make changes quickly without incurring additional costs for new plates. Plate printing is best for businesses that have a stable, well-established design.

Turnaround Time:
Digital printing usually offers a faster turnaround time because the setup process is much quicker. Plate printing requires more time for plate creation, press calibration, and other setup procedures, so you should plan for longer lead times, especially for larger runs.

Print Quality and Material Compatibility:
Plate printing excels in achieving high-quality prints with precise color matching and complex designs. It’s also better suited for certain material types, especially high-end barrier films or specialty finishes. Digital printing, while capable of producing great results, might not match the print quality and color consistency of rotogravure printing—particularly when it comes to large quantities.

Specialty Features:
If you need specialty features like metallic inks, embossing, or a combination of matte and gloss finishes, plate printing is the way to go. These intricate details are better achieved through rotogravure printing. Digital printing is improving, but these specialized effects remain a challenge for digital technologies.

Cost Considerations:
Digital printing has lower upfront costs, as it doesn't require printing plates. This makes it a better option for small runs. Plate printing has higher initial costs but becomes cheaper at scale, making it the most cost-effective option for larger orders.

When to Choose Digital or Plate Printing?

For small to medium-sized businesses, digital printing is often the best choice. It’s ideal for testing new products, launching limited editions, or switching between different designs. If you’re looking to produce fewer than 5,000 units per design, digital printing is generally more cost-effective and faster, making it perfect for smaller batches and greater design flexibility.

On the other hand, if you have a high-volume, consistent product line, or need to maintain color consistency across large orders, plate printing is the most cost-effective option at scale. Once you’ve settled on a design and you’re ready to make a large, consistent order, plate printing will ensure the best print quality and cost savings as you scale up.

Choosing between digital and plate printing depends on your specific needs. Digital printing is ideal for small to medium-sized runs, offering flexibility and quick turnaround, especially for businesses with evolving designs. Plate printing, on the other hand, is more cost-effective for large-scale orders, delivering superior print quality and consistency. By carefully considering your order size, design requirements, and budget, you can select the printing method that best supports your packaging goals.