Printing
Custom packaging printing
We match the print method to the run rather than pushing every job down the same route.
The routes we run
Digital for short runs, prototypes and versioned designs where plate costs cannot be justified. Offset lithography for volume board work where colour accuracy matters and spot colours need to print directly. Flexography for corrugated, film and bag substrates at volume. Screen printing for fabric and heavy ink lay applications.
The crossover between digital and plate-based printing usually sits between 1,000 and 3,000 units, earlier for single-colour work and later for complex multi-colour designs with finishing.
Where each route stops being economic is set out in the printing methods guide.
Colour management
Spot colours print directly from named inks on offset and flexo. Digital produces the closest process build, which is very close but not identical on critical brand colours.
On uncoated and kraft substrates every method prints warmer and duller than on coated white board. That is the material behaving normally. Where colour is critical we recommend a proof on the actual substrate rather than a generic proof stock.
Interior and specialty printing
Interior printing is available on mailers, folding cartons and rigid boxes. It earns its cost most clearly when the product does not fill the pack, because that is when the customer sees the inside face at opening.
White ink on kraft and clear substrates requires an opaque underbase so colours above it stay accurate. It adds a pass and a cost but is the only way to hold colour on a dark or transparent surface.
Interior print pays off most on formats the customer opens themselves, such as printed e-commerce mailers.
Get your print route quoted
Quantity, colours and substrate decide the method. Send those three and we will price the routes that genuinely apply rather than all of them.
No obligation
Request a quote
Send us the product details and quantity. We reply with a specification and a written price, usually within one business day.
Answers
Questions about custom packaging printing
Which print method suits my run?
Under about 1,000 units, digital almost always. Above about 3,000, offset or flexo depending on substrate. Between the two, ask for both prices at your exact quantity.
Can you match a specific Pantone?
On offset and flexo we print the Pantone ink directly. On digital we produce the closest process build, which differs slightly on critical brand colours.
How many colours can I use?
Digital handles full colour at no per-colour cost. Plate-based methods add a plate and a pass per colour, so colour count directly affects setup cost.
Do you print inside boxes?
Yes, on mailers, cartons and rigid boxes. It is most worth the cost when the product does not fill the pack.
Can you print on kraft board?
Yes. Expect colours to appear warmer and less saturated, and note that white requires an opaque underbase.
What is litho-lamination?
An offset-printed sheet bonded to corrugated board, giving photographic print quality that flexography cannot achieve directly. It costs more than flexo.
Can I print different versions in one run?
On digital, yes, with no extra setup. On plate-based printing each version needs its own plate set.
How consistent is colour across reorders?
We retain colour targets on file so reorders match. Offset holds the tightest run-to-run consistency of the available methods.
What resolution do images need?
300 dpi at the size the image appears on the finished pack, not at its original size.
Do you print metallic or fluorescent inks?
Yes on offset and screen printing. Digital simulates metallic effects rather than printing true metallic ink.
Next step
Tell us what you are packing
Send the product dimensions and the quantity you need. We come back with a specification, a lead time and a written price.