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Corrugated POP Display Printing

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Point-of-purchase (POP) displays are designed to capture shopper attention and influence buying decisions. Beyond structure and branding, the quality of print determines how well a display communicates from multiple viewing angles in a retail environment. Selecting the right printing method ensures your display performs both visually and functionally.


Printing Methods for Corrugated POP Displays

Not all printing methods are suited for corrugated displays. Each has its own strengths and trade-offs in cost, speed, quality, and run size. The three most common methods are:

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Flexographic Printing

Flexographic printing uses plates to apply ink as material passes through rollers.

Advantages

  • Cost-Efficient at Scale: Once plates are created, cost per unit is low for large or repeat orders.

  • Pantone Accurate: Ensures precise color matching across production runs.

  • Versatile: Works on uneven surfaces and a wide range of substrates.

  • High Speed: Suited for mass production.

Limitations

  • High Startup Costs: Plates and tooling are expensive, making short runs less economical.

  • Poor for Sampling: Costly and impractical to produce prototypes.

Best Fit: Large-volume retail displays where consistency and color accuracy are priorities.

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Digital Printing

Digital printing applies artwork directly from a file to the substrate, eliminating plates.

Advantages

  • Low Startup Cost: Cost-effective for short runs and prototypes.

  • Fast Turnaround: Ideal for tight deadlines or seasonal campaigns.

  • Flexible: Easily handles multiple SKUs or frequent artwork changes.

  • High Quality: Produces sharp graphics suitable for branded displays.

Limitations

  • Less Economical at Scale: Higher cost per unit for large volumes.

  • Color Variability: Approx. 95% accurate; not a perfect Pantone match.

  • Slower Mass Output: Not as efficient as flexographic presses for high quantities.

Best Fit: Small-batch retail displays, prototypes, or variable-data campaigns.

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Lithographic (Offset) Printing

Lithographic printing transfers ink from a plate to a rubber blanket, then onto the substrate, with options for coatings or varnishes.

Advantages

  • Highest Quality: Sharp, detailed graphics with accurate color reproduction.

  • Premium Finishes: Coatings and varnishes enhance durability and appearance.

  • Scalable: Handles small to large format prints.

Limitations

  • High Setup Cost: Plates and setup make short runs expensive.

  • Not Sample-Friendly: Prototypes are cost-prohibitive.

  • Longer Lead Time: Setup and adjustments require planning.

Best Fit: High-volume displays where premium image quality is essential for brand impact.`

corrugated pallet display

Designing Graphics for POP Displays

Effective POP displays combine structure with clear, impactful graphics. Common elements include:

  • Logos and Brand Colors

  • Product Imagery

  • Text (ingredients, instructions, contact info)

  • Symbols and Icons

  • Promotions or Pricing

  • Call-to-Action Messaging

  • Mascots or Characters

Any artwork provided must be adjusted to fit dielines correctly. Designers ensure bleed, folds, and structural features align with graphics to avoid misprints.


Choosing the Right Printing Method

When selecting a printing process, consider:

  • Quality: Lithographic offers the highest resolution; flexographic is durable but less detailed.

  • Budget and Quantity: Flexographic suits large runs, digital works best for small runs, lithographic for high-volume premium graphics.

  • Lead Time: Digital is fastest due to no plate requirements.

  • Brand Goals: For premium retail impact, lithographic justifies higher cost; for efficiency, flexographic is the workhorse.

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Buyer Takeaway

  • Use flexographic printing for large-scale runs that need durability and consistent Pantone colors.

  • Choose digital printing for prototypes, short runs, or campaigns with multiple SKUs.

  • Invest in lithographic printing for premium displays that require sharp, high-quality graphics.

Selecting the right method ensures POP displays not only stand out visually but also align with budget and timeline requirements.


References

  • Association of Independent Corrugated Converters (AICC). (2024). Printing Methods in Corrugated Packaging. Retrieved from https://www.aiccbox.org

  • Flexible Packaging Association. (2023). Digital vs. Flexographic Printing. Retrieved from https://www.flexpack.org

  • Robertson, G. L. (2016). Food Packaging: Principles and Practice (3rd ed.). CRC Press.

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Retail Ready Checklist for POP Displays

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In the dynamic realm of retail, crafting the perfect display goes beyond just showcasing products – it’s about sparking customer interest, driving sales, and making a lasting impression. Key to this success is the strategic use of point-of-purchase (POP) displays, which have the power to influence buying decisions at the crucial moment. This guide delves into the essential factors to consider when choosing the right materials for your retail displays, ensuring that your creations stand out and make a genuine impact. Balancing Cost and Quality Your choice of materials significantly affects your display’s overall cost and quality. While cardboard offers an affordable option, plastic strikes a balance between cost and durability. Higher-end materials like wood and metal communicate luxury, potentially enhancing the perceived value of your products. Ensuring Longevity and Durability Consider the intended lifespan of your displays. Corrugated cardboard suits short-term promotions, while plastic, metal, and wood are better suited for long-lasting and semi-permanent installations. Plastic excels in semi-permanent setups, whereas wood and metal offer robustness for prolonged use. Flexibility for In-Store Mobility The ease of movement is vital for logistics and adaptability within the store. Well-designed displays simplify assembly, shipping, and rearrangement. Lightweight materials like cardboard are easy to transport and assemble, while plastic and metal provide flexibility in placement. Safeguarding Products with Smart Design Product protection is paramount, especially for fragile or valuable items. Metal, plastic, and wood offer enhanced impact resistance compared to cardboard. Secure display options like wire tethers can deter theft and prevent accidental damage. Aesthetic Appeal and Brand Alignment Materials contribute to the overall visual and tactile experience of your displays, playing a pivotal role in conveying your brand’s identity. Cardboard offers versatility in design, plastic exudes modernity, wood brings in natural charm, and metal adds a touch of sophistication. The inclusion of electronic components elevates interactivity and brand engagement. Sustainability and Environmental Responsibility In today’s eco-conscious landscape, consider the environmental impact of your display materials. Cardboard is a standout option due to its recyclability, while permanent materials generate less waste. Wood can often be repurposed, and metal is endlessly recyclable – align your choices with your brand’s commitment to sustainability. Materials that Complement Product Vibes Harmonize your display materials with your product type to create a coherent and captivating presentation. Cardboard’s adaptability suits a range of products, plastic shines for clothing and sleek items, wood adds warmth for food and wine displays, and metal lends an industrial edge for electronics and snacks. If you are interested in point of purchase displays, then partner with Brown Packaging today. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Displays Facebook Twitter LinkedIn Pinterest Relevant Posts

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