Introduction
Digital printing machines are changing the rules of the game in the packaging industry, responding quickly to customer needs and achieving flexible small-batch production.
For packaging companies, digital printing means shorter proofing cycles and lower minimum order quantities. Customers can even place orders today and receive the goods tomorrow. Moreover, it can easily cope with personalized customization needs, whether it is variable data printing or unique pattern design, it can be completed efficiently.
In the long run, digital printing technology not only improves production efficiency, but also reduces material waste caused by traditional plate making, which is more in line with the current development trend of green environmental protection. This may be why more and more packaging factories are beginning to introduce digital printing equipment, which is becoming the new standard in the industry.
What is Digitally Printed Corrugated Cardboard Packaging?
Digital printing of corrugated cardboard packaging, to put it simply, is to use high-tech inkjet technology to print patterns directly on the carton, eliminating the tedious processes of traditional printing such as plate making and ink mixing. This technology is particularly suitable for the current market’s pursuit of speed, flexibility and change.
Key Advantages of Digitally Printed Corrugated Packaging
1. Zero threshold for minimum order, print as many as you want
Traditional printing often requires a minimum order of 500, while digital printing accepts orders even if it only prints one box. No longer need to be burdened by inventory funds, truly realize "printing on demand".
2. Simple process, fast delivery
Save the process of plate making and plate exposure, and print immediately after the design draft is confirmed.
3. Each box can be customized
In the same batch of goods, each carton can be printed with different copywriting and patterns.
4. High color accuracy
Traditional printing color adjustment is like opening a blind box, and digital printing is what you see is what you get. After the design draft is adjusted, the printout is basically not off, which is especially suitable for brand packaging with high color requirements.
5. Environmental protection and cost saving
No need to wash and change the plate, the ink utilization rate is as high as 95%, and the scrap rate is half lower than that of traditional printing.
Applications of Digitally Printed Corrugated Packaging
Digitally printed corrugated cardboard packaging is widely used across various industries, including:
- E-Commerce and Subscription Boxes
- Retail Packaging and Point-of-Sale Displays
- Food and Beverage Packaging
- Industrial and Logistics Packaging
- Event and Promotional Packaging
How Does Digital Printing Compare to Traditional Printing Methods?
| Feature | Digital Printing | Flexographic Printing | Offset Printing |
|---|---|---|---|
| Setup Time | Minimal | High | High |
| Best for | Short runs & custom designs | Large-volume orders | High-quality mass production |
| Color Options | Full-color, photo-quality | Limited spot colors | High-detail images |
| Personalization | Easily customizable | Not practical | Limited |
| Eco-Friendly | Uses less waste | Requires plates & chemicals | Requires plates & chemicals |
| Cost-Effectiveness | Best for small & mid-sized runs | Cost-effective for high-volume orders | Best for large-scale printing |
Challenges of Digital Printing on Corrugated Cardboard
1. Problems caused by low-grammage base paper
Using low-grammage base paper can lead to visible corrugation marks. A-type corrugated cardboard is particularly vulnerable, and printing presses can reduce its flat compression strength. Edge compression is also affected. Warped board may cause print misalignment and thickness reduction.
2. Problems caused by different surface roughness of base paper
Rough and loose paper structures absorb more ink and dry quickly. Smoother, denser papers dry slowly but offer better print resolution and image clarity. Coated white board papers, for example, absorb less ink but reproduce patterns better than tea board or boxboard.
3. Problems caused by differences in base paper absorption
Variations in raw materials, sizing, and coating create inconsistent ink absorption. For instance, coated white board paper and kraft card absorb ink slowly, requiring adjustments in ink concentration and viscosity across printing stages.
Future Trends in Digitally Printed Corrugated Packaging
- Competition with digital printing: Traditional methods must improve cost-efficiency and flexibility to stay relevant.
- Pressure of green certification: Stricter regulations push for cleaner inks, plates, and processes.
- Growth in emerging markets: Developing nations present massive demand for advanced printing solutions.
Summary
Digitally printed corrugated cardboard packaging is revolutionizing the packaging industry, offering high-quality graphics, fast production, and cost-effective short runs.
Digital corrugated cardboard printing machines are evolving toward greater precision, environmental friendliness, automation, and efficiency. These innovations help meet diverse market demands while addressing challenges like cost control and sustainability.