Lithography Vs Digital Print: Pros and Cons
Lithography and digital print are two of the most commonly used methods in packaging printing. They both have unique advantages and disadvantages, and understanding these differences can help you make an informed decision about which method is best for your packaging needs. In this blog, we’ll compare and contrast digital print and lithography in packaging.
Lithography
Lithography, also known as offset printing, is a traditional printing process that has been used for over a century. It involves the transfer of ink from a printing plate to a rubber blanket, which is then pressed onto the paper or packaging material. Lithography is a high-quality printing method that produces sharp, crisp, and detailed images with consistent color and density.
Advantages of Lithography
Lithography is a high-quality printing method that has been used for over a century and is known for its superior print quality. It is widely used in packaging printing for a variety of reasons, including its versatility, consistency, and cost-effectiveness for large runs. Here are some advantages of lithography in more detail:
- High-Quality Prints: Lithography produces high-quality prints with accurate color reproduction, sharp images, and consistent color and density. The printing plates used in lithography are carefully prepared, ensuring that each print is of the same quality as the first.
- Versatility: Lithography can be used on a wide range of packaging materials, including paper, corrugated and plastic. It is also suitable for printing on various shapes and sizes of packaging, making it a versatile option for packaging printing.
- Consistency: Because lithography uses printing plates, each print is consistent in quality and color. This makes it an ideal choice for large runs where consistency is essential.
- Cost-Effective for Large Runs: Lithography becomes more cost-effective for large runs because the cost of the printing plates can be spread over a large number of prints. This makes lithography a popular choice for large packaging orders.
- Excellent Detail and Resolution: Lithography produces prints with excellent detail and resolution, making it the ideal choice for printing complex designs and fine text.
Disadvantages of Lithography
While lithography has many advantages, it also has some disadvantages that should be considered when deciding whether to use this printing method for packaging. Here are some disadvantages of lithography in more detail:
- High Setup Costs: Lithography has a high setup cost because it requires the creation of a printing plate and the preparation of the printing press. This can make it less cost-effective for smaller runs of packaging.
- Long Lead Times: The setup process for lithography can take a long time, which can be a disadvantage when you need your packaging printed quickly. The process of creating the printing plates and preparing the printing press can take several days or even weeks, depending on the complexity of the design and the size of the print run.
- Limited Customization: Lithography is not the best choice for highly customized packaging as it requires the creation of a new printing plate for each design. This can be time-consuming and expensive, making lithography less suitable for small runs of packaging with different designs.
- Environmental Concerns: Lithography is not the most environmentally friendly printing method. The process uses chemicals and produces a lot of waste, including used ink, paper waste, and printing plates, which can be harmful to the environment if not disposed of properly.
Digital Printing
Digital printing is a newer printing technology that has been rapidly gaining popularity in recent years. It involves the direct transfer of digital files to the printing press, eliminating the need for printing plates.
Advantages of Digital Print
Digital print offers a range of advantages over traditional printing methods like lithography, making it an attractive option for many packaging applications. Here are some advantages of digital printing in more detail:
- Quick Turnaround: Digital printing has a much faster setup time than lithography, which means that your packaging can be printed quickly. There is no need to create printing plates, which eliminates the time-consuming process of plate making and setup.
- Cost-Effective for Small Runs: Digital printing is cost-effective for small runs of packaging because there are no setup costs associated with the printing plates. This makes digital printing an ideal choice for startups or small businesses that need a smaller number of packaging prints.
- Customization: Digital printing allows for a high degree of customization, making it ideal for unique and personalized packaging. Each print can be different without any additional costs, which is perfect for packaging with multiple versions or personalized designs.
- High-Quality Prints: While digital printing may not match the print quality of lithography, it has come a long way in recent years and can produce high-quality prints with accurate color reproduction, sharp images, and excellent detail and resolution.
- Versatility: Digital printing is suitable for a wide range of packaging materials, including paper, corrugated, plastic, and some types of metal. This makes it a versatile option for packaging printing that can be used in a variety of applications.
Disadvantages of Digital Print
Although digital printing has many advantages, it also has some disadvantages that should be considered when deciding whether to use this printing method for packaging. Here are some disadvantages of digital printing in more detail:
- Lower Print Quality: While digital printing has come a long way in recent years, it still cannot match the print quality of lithography. Digital printing can produce high-quality prints, but the color reproduction, sharpness, and detail may not be as accurate or consistent as lithography.
- Limited Versatility: While digital printing is suitable for a wide range of packaging materials, it may not be the best choice for all materials. Digital printing may not be suitable for some packaging materials like glass or some types of metal. Additionally, digital printing may not be able to achieve some specialty finishes, such as metallic inks or embossing.
- Inconsistent Color Matching: Because digital printing does not use the same ink as lithography, color matching can be challenging, especially when it comes to Pantone colors. Variations in temperature, humidity, and the printing substrate can also affect color accuracy.
- Limited Longevity: Digital prints may not last as long as lithographic prints. The ink used in digital printing can fade or degrade over time, particularly if the print is exposed to sunlight or other environmental factors.
If your interested in printed packaging, then partner with Brown Packaging today to get started.
In 2026, sustainability is no longer just a trend—it’s a buyer expectation. Forest Stewardship Council (FSC) certification has become a key benchmark for responsible packaging, signaling that materials are sourced from responsibly managed forests. For packaging buyers, FSC certification is more than a compliance checkbox—it’s a brand value that influences purchasing decisions, retailer acceptance, and customer loyalty. What Is FSC Certification? The Forest Stewardship Council certifies that paper-based packaging materials are sourced from forests managed for environmental responsibility, social benefit, and economic viability. FSC Mix: Packaging contains a blend of FSC-certified and controlled wood. FSC Recycled: Packaging is made entirely from recycled fiber. FSC 100%: Packaging is sourced only from FSC-certified forests. Why FSC Matters to Buyers in 2026 Retail access: Many major retailers now require FSC-certified packaging. Sustainability goals: Aligns with corporate ESG and carbon reduction commitments. Consumer trust: Customers recognize the FSC label and view it as credible. Global compliance: Meets international sustainability regulations. How FSC Certification Strengthens Brand Value Differentiation: Stand out with certified sustainable packaging. Marketing advantage: FSC logos reinforce eco-friendly messaging. Risk reduction: Verified sourcing prevents greenwashing claims. Customer loyalty: Environmentally conscious buyers prefer certified products. Challenges in FSC Implementation Limited supply of certain FSC substrates. Higher costs compared to non-certified materials. Need for supplier audits and documentation. Packaging Solutions with Brown Packaging Brown Packaging partners with buyers to integrate FSC-certified materials into corrugated boxes, folding cartons, and retail packaging. Our solutions support sustainability while maintaining cost efficiency and protection. Contact us to strengthen your brand with FSC-certified packaging. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Consumer Insights on Sustainable Packaging. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Sustainability is now a top priority for packaging buyers. Retailers, regulators, and consumers are all demanding packaging solutions that reduce environmental impact without sacrificing performance. In 2026, buyers must balance eco-friendly materials, cost, and compliance to build programs that are both effective and future-ready. What Buyers Need to Know About Sustainable Packaging Regulatory pressure: Governments are enforcing stricter rules on recyclability and plastic use. Retail mandates: FSC certification and recyclable packaging are becoming standard requirements. Consumer expectations: Customers increasingly choose brands with visible sustainability commitments. Sustainable Material Options Recycled corrugated: High recycled content while maintaining compression strength. Compostable films: Suitable for select food and retail applications. Molded pulp inserts: Replace foam or plastic for protective packaging. Water-based coatings: Enhance moisture resistance without harmful chemicals. Balancing Cost and Performance Right-size packaging: Reduces material waste and shipping costs. Hybrid solutions: Combine eco-materials with corrugated for balance. Life cycle analysis: Evaluate true environmental impact, not just marketing claims. How to Evaluate Sustainable Suppliers Verify FSC, SPC, or ISO certifications. Request testing data for durability and recyclability. Audit supply chains for consistency and transparency. Ensure claims meet local and international compliance standards. Packaging Solutions with Brown Packaging Brown Packaging helps buyers implement sustainable packaging programs that balance cost, performance, and compliance. From recycled corrugated to eco-friendly coatings and inserts, we deliver solutions that meet 2026 sustainability goals. Contact us to explore sustainable packaging options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Packaging Sustainability Trends and Buyer Insights. Retrieved from https://sustainablepackaging.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (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. Sustainable Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Choosing the right packaging material is one of the most important decisions buyers face. Single-material packaging offers simplicity and recyclability, while multi-material designs provide enhanced performance and protection. Understanding the trade-offs helps companies balance cost, functionality, and sustainability goals in 2026. What Is Single-Material Packaging? Single-material packaging uses one substrate—such as corrugated board, folding carton, or plastic—for the entire structure. Advantages: Easier to recycle and dispose. Lower material costs in many cases. Streamlined sourcing and inventory. Supports sustainability messaging. Disadvantages: Limited barrier protection. Less customization for fragile or complex products. May require added thickness for strength, increasing weight. What Is Multi-Material Packaging? Multi-material packaging combines two or more substrates—such as corrugated with foam, or paperboard laminated with film—to achieve specific performance outcomes. Advantages: Greater protection against moisture, oxygen, and impact. Allows for premium finishes and enhanced graphics. Ideal for fragile or high-value products. Customizable for unique supply chain conditions. Disadvantages: More difficult to recycle due to material separation. Higher cost and longer lead times. Complex sourcing and inventory management. When to Use Each Approach Single-material packaging: Best for products with low fragility, strong sustainability requirements, or cost-driven programs. Multi-material packaging: Best for high-value, fragile, or regulated products requiring advanced protection. Balancing Performance and Sustainability Buyers must weigh performance needs against eco goals: Use recyclable coatings to extend single-material performance. Choose hybrid designs that separate easily for recycling. Apply multi-material solutions only where risk of damage outweighs cost. Packaging Solutions with Brown Packaging Brown Packaging helps buyers evaluate when to use single- vs. multi-material packaging. Our team balances sustainability, performance, and cost to deliver solutions tailored to your supply chain. Contact us to explore the right approach for your products. References Forest Stewardship Council (FSC). (2023). FSC Packaging Certification Guidelines. Retrieved from https://fsc.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability and Multi-Material Packaging Report. Retrieved from https://sustainablepackaging.org (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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
One of the biggest challenges in sustainable packaging is balancing environmental responsibility with product protection. Buyers often worry that switching to eco-friendly materials means sacrificing durability or driving up costs. In 2026, new material technologies allow brands to meet sustainability goals without compromising strength or supply chain performance. Why Protection Still Matters Damaged products create more waste than packaging ever could. Returns increase logistics costs and carbon emissions. Retailers and e-commerce platforms expect packaging to deliver both sustainability and reliability. Eco-Friendly Material Options Recycled corrugated: Maintains stacking strength while reducing virgin fiber use. Molded pulp inserts: Cushion fragile items while replacing plastic foam. Water-based barrier coatings: Add moisture resistance without plastic films. Compostable films: Ideal for short shelf-life or single-use applications. Paper-based mailers: Replace poly mailers for e-commerce shipments. How to Balance Eco Goals and Protection Use right-sizing to reduce material volume while improving fit. Apply hybrid solutions (corrugated + pulp) for high-value goods. Conduct ISTA testing to validate protective performance. Match material choice to product fragility and supply chain conditions. Examples in Action Electronics: Molded pulp trays replacing EPS foam. Food and beverage: FSC-certified corrugated with recyclable coatings. Retail e-commerce: Recycled paper mailers protecting apparel. Packaging Solutions with Brown Packaging Brown Packaging develops eco-friendly solutions that protect products while meeting sustainability requirements. From recycled corrugated to innovative coatings, our team ensures you never trade protection for environmental impact. Contact us to explore eco-material options. References Forest Stewardship Council (FSC). (2023). FSC Certification Guidelines for Packaging. Retrieved from https://fsc.orgSustainable Packaging Coalition. (2023). Eco-Friendly Packaging Materials and Case Studies. Retrieved from https://sustainablepackaging.orgASTM International. (2023). ASTM D4169: Standard Practice for Performance Testing of Shipping Containers and Systems. (714)300-0650 request@brownpackaging.com Most Recent Posts: Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
In today’s competitive market, packaging affordability doesn’t start with cheaper materials — it starts with smarter design. Every score, fold, and insert decision affects not only how a box looks and feels, but how efficiently it’s made, shipped, and used. Structural engineering is the silent driver of cost efficiency — optimizing strength, space, and performance before the first sheet is ever printed. Why Structure Matters More Than You Think The most impactful cost savings in packaging rarely come from supplier discounts; they come from structural efficiency.A box that uses 10% less board but maintains the same compression strength directly reduces both material and freight cost. A redesigned insert that eliminates the need for secondary packaging saves time and labor at the line. Every cut line and fold path tells a story of cost, sustainability, and brand care — and when those align, affordability becomes part of your brand’s DNA. Designing for Efficiency, Not Excess In a market saturated with overbuilt packaging, engineering restraint is a competitive advantage. Structural teams now rely on 3D CAD modeling and virtual prototyping to simulate performance before production — identifying unnecessary material use and structural redundancies. Through precision die-line planning, engineers can improve sheet yield, reduce assembly time, and minimize void space — the dead air that drives up freight bills.It’s not about doing less; it’s about doing smarter. Balancing Protection and Presentation The temptation to “overprotect” products is common — especially in fragile or high-value goods. But protection doesn’t have to mean bulk. Strategic reinforcements, engineered fluting, and interlocking designs can maintain crush resistance and shock absorption while reducing total board weight. For e-commerce and shelf packaging alike, brands can achieve premium presentation with structural simplicity — a key to making packaging both sustainable and affordable. Prototyping to Prevent Waste Prototyping isn’t just for aesthetics — it’s a safeguard against costly production errors.With short-run sample testing and performance mockups, brands can evaluate fit, function, and protection early in development. Adjusting dimensions by fractions of an inch can save thousands in material waste and prevent rejected runs down the line. Smart packaging buyers now view prototyping not as an expense, but as a cost-control strategy that pays dividends in scale. How Structural Design Supports Brand and Budget Affordable design doesn’t mean compromising brand identity — it means integrating brand goals into structure. A well-engineered box reinforces trust, ensures product consistency, and communicates value through precision and fit. When structure, design, and production align, packaging stops being a cost and starts becoming a business asset. That’s where the real savings live — and where long-term brand equity begins. The Brown Packaging Difference At Brown Packaging, every packaging solution starts with structural intent — not guesswork.Our engineering and design teams collaborate to create packaging that performs across shipping, retail, and automation lines, balancing protection, brand visibility, and cost efficiency. We don’t cut corners; we cut waste.That’s how our clients achieve packaging that’s not just affordable — it’s engineered to perform. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. PMMI. (2024). Optimizing Structural Design for Packaging Efficiency. Packaging World. (2025). Engineering the Future of Cost-Effective Packaging. Smithers. (2025). Packaging Innovation and Material Efficiency Trends. (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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Every brand is feeling the squeeze — higher raw material costs, volatile freight rates, and a consumer base more price-conscious than ever. But cutting packaging budgets blindly can lead to damaged goods, compliance issues, and eroded brand value. Smart brands aren’t chasing cheaper boxes — they’re making smarter packaging decisions that balance performance, cost, and perception. The difference between saving money and losing value comes down to how you evaluate your packaging, not just what you pay for it. Beyond Unit Price: Understanding Total Packaging Cost A low unit price might look great on paper — until you factor in assembly time, damage rates, and freight efficiency. Smart packaging evaluation considers the total cost of ownership, including: Material yield (how efficiently sheets convert into boxes) Pallet and trailer utilization (freight optimization) Labor efficiency (ease of assembly or automation compatibility) Product protection (damage rates, replacements, and returns) When buyers assess all these metrics, the lowest-cost box often isn’t the best-value box. Material Selection That Saves in the Long Run Switching materials isn’t just about cutting cost — it’s about reducing waste and improving performance. For instance, moving from double-wall to a high-performance single-wall with better flute structure can cut weight and shipping cost without sacrificing protection. In folding cartons, substrate optimization — using a lighter caliper SBS or switching to coated recycled board — can yield savings that scale across production runs. And for rigid boxes, structural tweaks like thinner chipboard paired with strong wrap papers can preserve presentation while reducing material use. Every small change adds up when you scale across thousands of units. Design Efficiency: The Overlooked Cost Saver A smart structural design can eliminate cost before production even starts. Simplifying folds, reducing glue flaps, or reengineering inserts can cut assembly time and material waste. Modern packaging engineers use CAD-based dieline analysis to optimize layouts — ensuring maximum sheet yield and minimal offcut. For e-commerce and retail brands alike, right-sizing packaging improves shipping efficiency and reduces filler materials while maintaining the brand’s polished look. It’s not just design — it’s design that earns its keep Printing Smart: Matching the Process to the Purpose Not every job needs premium litho or complex spot varnishes. A good packaging partner matches print method to scale and brand intent: Flexo printing for high-volume, cost-efficient runs. Digital printing for short runs, personalization, and multi-SKU campaigns. Litho laminating for high-end visuals in rigid or premium retail displays. By choosing the right print method early, brands can avoid over-engineering — saving both time and money without compromising quality. Data-Driven Decisions: The New Standard for Packaging Buyers Leading companies now use data to guide packaging spend. Damage rate metrics, SKU-level freight analysis, and consumer perception studies all contribute to smarter choices. Smart buyers are no longer asking, “What’s the cheapest box?” They’re asking, “What’s the most efficient box that protects the product, ships well, and supports brand goals?” This mindset shift is what separates cost-cutting from cost control. The Brown Packaging Approach At Brown Packaging, we help brands make smarter packaging decisions by combining engineering analysis, supplier network leverage, and real-world testing. Our process aligns packaging performance with total cost goals — from box design to print selection and logistics. The result: stronger packaging, lower waste, and sustainable cost savings that scale with your business. Because in today’s market, smart packaging isn’t just a cost center — it’s a competitive advantage. References PMMI. (2025). Operational Cost Efficiency in Packaging and Logistics. McKinsey & Company. (2024). Total Cost of Ownership in Consumer Goods Packaging. Packaging World. (2025). Data-Driven Decisions in Packaging Sourcing. Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). (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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
By submitting your information, you agree to our terms and conditions and privacy policy.
Printed boxes are an excellent choice for enhancing brand visibility and creating a memorable unboxing experience for customers. However, a common concern is whether they maintain their aesthetic appeal after enduring the shipping process, which often involves rough handling, exposure to dirt, and environmental factors. In this blog, we’ll explore the challenges of keeping printed boxes looking great during shipping and share actionable tips to ensure your packaging stays pristine and professional, no matter the journey. Why Do Printed Boxes Get Dirty or Damaged During Shipping? Shipping environments can be harsh on packaging, especially when boxes are subjected to: Rough Handling: Boxes are frequently tossed, stacked, and dragged, which can cause scuffs, tears, or dents. Environmental Exposure: Rain, humidity, or dusty conditions can leave marks or stains on your boxes. Extended Transit Times: Longer journeys increase the risk of damage due to repeated handling and exposure. These factors can affect the appearance of printed designs, potentially diminishing the customer experience. How to Keep Printed Boxes Looking Great During Shipping Choose Durable Materials The quality of your box material plays a key role in protecting its appearance. Use corrugated cardboard with a robust outer liner for extra durability. Opt for laminated or coated surfaces to resist dirt, water, and scratches. Consider using kraft exteriors for rugged protection, with printed branding on the interior for a surprise-and-delight unboxing moment. Protect Your Print Design with Finishes A protective finish can safeguard your printed design against smudges, scratches, and moisture. Popular options include: Gloss Lamination: Adds a shiny finish that repels dirt and fingerprints. Matte Lamination: Offers a sophisticated, non-reflective look while protecting the print. UV Coating: Provides extra durability and is ideal for vibrant colors. Use Protective Shipping Features Additional shipping precautions can help reduce wear and tear. Add shrink wrap or polybag covers to shield boxes from dirt and moisture. Use double-boxing for high-value shipments to protect printed boxes during transit. Include void fillers like packing paper or air pillows to minimize movement inside the box. Avoid Overly Dark Designs on High-Impact Areas Dark colors, especially on corners or edges, are more likely to show scuffs or scratches. Reserve darker hues for less exposed areas of the box. Use lighter, neutral tones or patterns that help conceal minor wear. Choose Strategic Placement for Printing Where you print on the box matters. Print your branding or designs on the top and sides, leaving the bottom unprinted to reduce visible wear. For a luxury feel, consider printing inside the box to protect your design while providing a clean unboxing experience. Why Maintaining Box Aesthetics Matters The appearance of your packaging has a direct impact on your brand perception: First Impressions: A box that looks professional upon arrival reassures customers about your product quality. Brand Visibility: Pristine printed boxes keep your logo and messaging clear, acting as mobile advertisements during transit. Customer Loyalty: Packaging that withstands shipping challenges shows customers you value their experience. Conclusion Printed boxes can maintain their beauty and functionality during shipping with the right materials, finishes, and protective strategies. By investing in durable designs and smart shipping practices, you can ensure your packaging arrives looking as great as when it left your facility. If you are interested in quality printed corrugated boxes, then partner with Brown Packaging today to get started. (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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Corrugated boxes are essential to shipping, retail, and e-commerce—but when you introduce custom printing, the stakes (and the opportunities) rise. Print isn’t just about looks—it’s about communication, branding, compliance, and customer experience. Whether you’re designing a basic shipper or a bold, shelf-ready display, printing smart can save money and elevate your packaging. Here are 12 essential print tips to help buyers make informed decisions when sourcing printed corrugated boxes. Start With Purpose Before Design Are you trying to impress in-store, create a branded unboxing experience, or simply add a logo to a shipper? Your goal will determine how much print you need—and which method is best. Know the Three Main Print Methods Flexographic (Flexo): Cost-effective for simple graphics and large runs Digital: Great for short runs, versioning, or quick turnarounds Litho (Litho-Label): High-end graphics mounted to the box for premium results Choose based on your volume, detail level, and budget. Understand Your Print Surface Corrugated comes in kraft (brown) and white surfaces. White gives better color accuracy Kraft offers an organic, eco-conscious look Your surface will affect how your design prints—especially with flexo. Keep Artwork Simple for Flexo Flexo printing uses plates and works best with limited colors, bold text, and clean logos. Avoid gradients, fine details, or small fonts unless you’re going digital or litho. Use Vector Files and High-Res Assets Always supply artwork in vector format (AI, EPS, or PDF) for scalability and sharp print. Images should be 300 DPI or higher. Low-res files can distort or blur during printing. Design Around the Dieline Your design should be laid out directly on the box dieline. This ensures correct placement of logos, cut lines, folds, and glue areas—so nothing important gets trimmed or hidden. Limit Ink Coverage to Reduce Cost Full-coverage ink areas (flood coats) require more material and setup. Consider printing only on key panels or using the box’s natural color to create contrast and cut costs. Test Color on Corrugated First Colors will appear differently on kraft vs. white corrugated and on different print methods. Always ask for a sample or press proof to verify color before production. Use Pantone Colors (When Needed) For brand consistency, especially with logos or specific brand colors, use Pantone Matching System (PMS) inks instead of CMYK—especially in flexo. Balance Design with Function Your print layout should enhance the box, not interfere with it. Avoid placing fine graphics near flaps, folds, or high-stress areas where cracking or misalignment can occur. Consider Print Inside the Box Want to wow customers or reinforce your brand? Add inside print for messaging, graphics, or product instructions. It adds impact—especially for e-commerce or subscription boxes. Always Review a Physical Proof (If Possible) Before full production, ask for a printed sample or digital proof to catch any errors in layout, registration, or color. This step can save time, cost, and frustration down the line. Final Thoughts Printing on corrugated boxes adds incredible value—but only if it’s done right. From selecting the right method to preparing artwork properly, these print tips help ensure your packaging performs as well as it looks. Need guidance on printed corrugated boxes? We’ll help you choose the best structure, material, and print approach to match your goals and your brand. (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. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Folding cartons are one of the most versatile forms of retail packaging—and how you print on them can make the difference between a product that blends in and one that commands attention. Strategic printing isn’t just about aesthetics; it’s about communicating value, increasing shelf appeal, and making your packaging work harder without adding cost. Here’s how to use print effectively to elevate your folding cartons—whether you’re working with skincare, supplements, food, electronics, or lifestyle products. Use Print to Create Visual Hierarchy Your folding carton only has a few seconds to make an impression on the shelf. Strategic printing helps guide the customer’s eye to what matters most. Tips: Use bold, contrasting colors or finishes (spot UV, foil) to highlight your brand name or logo Place key selling points (benefits, claims, features) front and center using larger font sizes Use typography and spacing to separate messaging and improve readability ✅ Helps the customer immediately understand what your product is and why it matters ✅ Improves visual impact without changing the structure ✅ Reduces reliance on costly redesigns by making the most of layout Match Print Quality to Product Value Your packaging should reflect the value of the product inside. Low-quality print on a premium item creates confusion—or worse, distrust. Use printing to reinforce brand perception. Recommendations: For high-end products, use offset or digital printing with high-resolution artwork Consider soft-touch coating, foil stamping, or embossed logos to enhance tactile appeal For entry-level products, clean flexo printing with sharp colors and simple messaging works well ✅ Aligns packaging with price point ✅ Builds customer trust and perceived quality ✅ Supports brand consistency across SKUs Make the Most of Every Panel Most folding cartons have six printable panels—front, back, two sides, top, and bottom. Don’t waste the real estate. Strategies: Use side panels for storytelling: sustainability efforts, brand values, QR codes Use bottom or inner flaps for certifications or required disclosures Add interactive elements (e.g., scan-to-learn codes) to drive post-purchase engagement ✅ Adds value without extra packaging ✅ Keeps primary panels clean and uncluttered ✅ Improves consumer education and brand connection Use Print to Simplify SKU Management For brands managing multiple SKUs or flavor/variant lines, digital printing or smart layout choices can reduce production complexity. Tactics: Create a shared dieline with only small design changes per SKU (e.g., color blocks, product names) Use black plate changes to keep core branding consistent while personalizing each version Leverage short-run digital printing for seasonal or promotional packaging ✅ Reduces setup and plate costs ✅ Increases flexibility for new launches ✅ Speeds up time to market for new variants Print for Retail Compliance Many retailers—especially in food, supplement, and cosmetic categories—have strict requirements around what’s displayed and where. Best practices: Print barcodes and expiration dates in scannable, clearly defined areas Use appropriate font sizes and spacing for ingredients, warnings, or supplement facts Leave space for lot coding or labeling if filled after printing ✅ Helps avoid costly chargebacks or relabeling ✅ Ensures legal compliance and customer clarity ✅ Streamlines vendor approvals Create a Memorable Unboxing Moment Folding cartons aren’t just for shelves—they also deliver an unboxing experience. The inside of the carton is an underutilized branding space. Ideas: Print a thank-you message or tagline inside the top flap Include hidden branding, illustrations, or QR codes inside the box Use the interior to reinforce key product benefits or cross-sell other products ✅ Turns packaging into a brand moment ✅ Encourages sharing and customer loyalty ✅ Adds value without structural changes Keep Production Methods in Mind Not every finish or design choice works with every printing method. Knowing the strengths of each helps you make the most cost-effective decision: Digital printing is perfect for small batches, personalized runs, or multiple SKUs Offset printing is ideal for high-quality retail packaging in larger volumes Flexographic printing is budget-friendly for basic folding cartons or larger quantities with simpler designs ✅ Ensures print decisions align with volume, speed, and budget ✅ Reduces production delays and unexpected costs Final Thoughts Your folding carton is more than just a box—it’s your on-shelf sales rep, brand ambassador, and customer touchpoint all in one. Strategic use of print can transform ordinary packaging into a powerful marketing tool, helping you communicate, connect, and convert. Need help making your folding carton print work harder? We’ll help you choose the right design, layout, and print method to bring out the best in your packaging—without overcomplicating your process or budget. (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. Folding Carton Facebook Twitter LinkedIn Pinterest Relevant Posts