Introduction
Printing plays a crucial role in corrugated cardboard packaging, affecting branding, product presentation, and information clarity. Businesses use printed packaging to enhance marketing appeal, improve logistics, and comply with labeling requirements.
There are two main methods of printing on corrugated cardboard:
- Pre-Printing: Printing on linerboard before it is laminated onto the corrugated sheet.
- Post-Printing: Printing directly on the finished corrugated board after it has been assembled.
Each method has unique advantages, limitations, and best-use cases, which we’ll explore in this guide.
What is Pre-Printing?
Pre-printing is the process of printing on the linerboard (outer paper layer) before it is combined with the corrugated fluting. This technique is commonly used in high-volume packaging production, where high-quality visuals are required.
How Pre-Printing Works
- The linerboard (flat paper) is printed using flexographic, gravure, or offset printing.
- The printed sheets are stored in rolls until needed for corrugation.
- During the corrugation process, the printed linerboard is laminated onto the fluted medium.
- The final sheets are then cut, folded, and assembled into boxes.
Advantages of Pre-Printing
✅ High-Quality, Full-Color Printing
- Produces sharp images, vibrant colors, and detailed branding.
- Allows for photo-realistic graphics and complex designs.
✅ Smooth and Even Surface
- Since printing is done on flat paper before corrugation, there are no distortions, warping, or ink absorption issues.
✅ Cost-Effective for Large Runs
- Pre-printing is ideal for bulk production, reducing per-unit costs.
- Commonly used in retail and consumer packaging where visual appeal is essential.
✅ Better Coating and Lamination Options
- Can apply gloss, matte, UV, or water-resistant coatings before corrugation.
- Helps protect packaging against moisture, fading, and damage.
Disadvantages of Pre-Printing
❌ Higher Initial Costs
- Requires specialized printing equipment and large paper rolls.
- Not suitable for small or customized print runs.
❌ Longer Lead Time
- The additional lamination and corrugation process extends production time.
❌ Limited Flexibility for Customization
- Pre-printed designs cannot be changed easily for small orders or individual packaging variations.
What is Post-Printing?
Post-printing is the process of printing directly onto the corrugated board after it has been manufactured. This method is widely used for e-commerce packaging, shipping boxes, and bulk storage cartons.
How Post-Printing Works
- Corrugated cardboard sheets are fully assembled (linerboard + fluting).
- The sheets are fed into a printing press, where ink is applied directly to the surface.
- Drying and finishing steps ensure print stability.
- The printed sheets are then cut, creased, and folded into final box shapes.
Advantages of Post-Printing
✅ Lower Cost for Small and Medium Runs
- No need for large paper rolls or complex setup.
- Ideal for short-run and on-demand packaging.
✅ Faster Turnaround Time
- Reduces production time by printing directly on finished boxes.
- Best for custom orders, last-minute packaging updates, and seasonal promotions.
✅ Flexible Customization Options
- Supports variable data printing, including barcodes, QR codes, and personalized branding.
- Allows for small-batch printing without extra costs.
✅ Cost-Effective for Shipping and Storage Boxes
- Best for functional, industrial, and logistics packaging that does not require premium graphics.
Disadvantages of Post-Printing
❌ Lower Print Quality Compared to Pre-Printing
- Printing on corrugated surfaces may cause distortions, color variations, and ink absorption issues.
- Not suitable for photo-realistic or complex designs.
❌ Limited Ink and Coating Options
- Cannot apply glossy or laminated finishes as effectively as pre-printing.
❌ Ink Smudging and Inconsistencies
- Uneven cardboard surfaces can result in blurry or misaligned prints.
Comparison: Pre-Printing vs. Post-Printing
| Feature | Pre-Printing | Post-Printing |
|---|---|---|
| Printing Process | On linerboard before corrugation | Directly on finished corrugated sheets |
| Best for | High-end, retail, and consumer packaging | Shipping boxes, logistics packaging |
| Print Quality | High resolution, full-color | Moderate quality, limited color options |
| Customization | Difficult (bulk production required) | Flexible (supports variable data printing) |
| Production Cost | Higher initial investment, lower cost per unit for large runs | Lower setup costs, cost-effective for small runs |
| Turnaround Time | Longer due to corrugation process | Faster production speed |
Choosing the Right Printing Method
Use Pre-Printing If:
✅ You need high-quality graphics and branding.
✅ Your packaging requires gloss, UV coatings, or laminated finishes.
✅ You are producing large volumes of packaging.
Use Post-Printing If:
✅ You need low-cost, functional printing for bulk boxes.
✅ Flexibility for custom orders, barcodes, and tracking numbers is required.
✅ You want a fast turnaround for e-commerce and shipping packaging.
Future Trends in Corrugated Cardboard Printing
The packaging industry is evolving, and new printing technologies are bridging the gap between pre-printing and post-printing.
1. Growth of Digital Printing
- Digital printing is now capable of full-color, high-resolution graphics directly on corrugated cardboard.
- Ideal for customized, short-run packaging.
2. Sustainability and Eco-Friendly Inks
- More companies are shifting to water-based and soy-based inks for greener printing solutions.
- Reducing the use of plastics and laminates to enhance recyclability.
3. Hybrid Printing Technologies
- New hybrid printing solutions combine pre-printing precision with post-printing flexibility.
- Brands can now achieve high-quality prints on demand without large inventories.
Summary
Both pre-printing and post-printing play essential roles in corrugated cardboard packaging, depending on budget, branding needs, and order volume.
- Pre-Printing is best for high-quality, full-color packaging in large volumes.
- Post-Printing is ideal for customizable, cost-effective, and functional shipping boxes.
With advancements in digital printing and eco-friendly technologies, businesses now have more options than ever to optimize their corrugated packaging solutions.