Digital vs Flexographic Printing: Which Is Right for Your Brand?

Choosing the right printing method for your flexible packaging is one of the most important decisions you’ll make when launching a new product or refreshing an existing range. It affects everything from lead times and minimum order quantities to design flexibility, print quality and overall cost.

Two of the most common printing technologies used for flexible packaging are digital printing and flexographic printing. While both can produce high quality packaging, they are designed for different production requirements.

Understanding the differences can help you select the solution that best supports your business today while allowing room for future growth.

What Is Digital Printing?

Digital printing is a modern printing process that transfers artwork directly onto packaging material without the need for printing plates.

Unlike traditional printing methods, every design can be changed instantly, making digital printing ideal for brands that value flexibility, speed and customisation.

At ePac Flexible Packaging, we use HP Indigo digital presses to produce premium flexible packaging with exceptional colour accuracy and image quality.

Digital printing is particularly well suited to:

• New product launches
• Seasonal and limited edition packaging
• Product testing
• Frequent artwork updates
• Small and medium production runs
• Personalised packaging campaigns

Because there are no plates to produce, projects move into production much faster.

What Is Flexographic Printing?

Flexographic printing, often called flexo printing, is a traditional printing method that uses flexible printing plates to transfer ink onto packaging materials.

Before production begins, individual plates must be created for every colour used in the design. While this increases the initial setup cost and production time, flexographic printing becomes highly economical when producing very large volumes.

Flexographic printing is commonly used for:

• High volume production
• Long term packaging designs
• Products with consistent artwork
• Large national or international product ranges

Many global brands use flexographic printing for products that require millions of identical packs.

Digital Printing vs Flexographic Printing

Although both technologies produce excellent packaging, they differ in several important areas.

Minimum Order Quantities

One of the biggest advantages of digital printing is flexibility.

Traditional flexographic printing usually requires larger production volumes to offset the cost of printing plates and setup.

Digital printing eliminates these setup costs, allowing brands to order exactly what they need.

This is particularly valuable for:

• Start-ups
• Growing businesses
• Businesses with multiple SKUs
• Brands launching new flavours or products

Ordering smaller quantities also reduces the risk of holding obsolete packaging if regulations, ingredients or branding change.

Lead Times

Speed has become increasingly important in today’s competitive marketplace.

Digital printing significantly reduces production times because there is no need to manufacture printing plates or complete lengthy press setup procedures.

This means brands can:

• Launch products faster
• React to market trends
• Restock packaging more quickly
• Reduce warehouse inventory

For businesses operating in fast-moving industries such as snacks, coffee, pet food and nutritional supplements, shorter lead times can provide a valuable competitive advantage.

Design Flexibility

Consumer preferences change quickly.

With digital printing, updating artwork is straightforward.

Whether you need to:

• Introduce a new flavour
• Update nutritional information
• Refresh your branding
• Create seasonal packaging
• Produce country-specific designs

changes can often be implemented without the additional costs associated with new printing plates.

Flexographic printing is better suited to packaging designs that remain unchanged for long production cycles.

Print Quality

Modern digital printing technology delivers exceptional image quality, sharp detail and smooth colour gradients.

This makes it particularly effective for:

• Premium food packaging
• Coffee packaging
• Beauty and personal care products
• Nutritional supplements
• Luxury products

High resolution photography, intricate illustrations and vibrant colours are reproduced with outstanding consistency.

Flexographic printing has also advanced considerably and produces excellent results, particularly on high volume production runs. However, digital printing often provides greater consistency across shorter runs and frequent design changes.

Cost Considerations

Many businesses assume digital printing is always more expensive.

In reality, the most cost effective option depends on production volume.

Digital Printing Can Reduce Costs By:

• Eliminating plate costs
• Reducing inventory
• Preventing obsolete packaging
• Lowering minimum order quantities
• Making product testing more affordable

Flexographic Printing Can Reduce Costs When:

• Producing extremely large quantities
• Artwork remains unchanged for long periods
• The same packaging is printed repeatedly

Rather than focusing only on the cost per pack, businesses should consider the total cost of ownership, including storage, waste and flexibility.

Sustainability Benefits

Packaging sustainability is becoming an increasingly important consideration for both brands and consumers.

Digital printing can support sustainability by helping businesses:

• Order only what they need
• Reduce packaging waste
• Minimise obsolete inventory
• Produce packaging closer to demand

Instead of storing thousands of unused pouches, brands can print in smaller batches as required.

This approach helps reduce unnecessary waste while improving inventory management.

Which Industries Benefit Most from Digital Printing?

Digital printing is particularly valuable for businesses with diverse product ranges or rapidly changing packaging requirements.

Industries that frequently benefit include:

Coffee

New blends, seasonal roasts and limited editions can all be launched without committing to large packaging inventories.

Pet Food

Multiple recipes and pack sizes become easier to manage with shorter production runs.

Nutritional Supplements

Frequent product launches and regulatory updates make digital printing an ideal solution.

Snacks and Confectionery

Limited editions and promotional packaging can be introduced quickly without large upfront costs.

Beauty and Personal Care

Premium graphics and smaller production quantities support growing brands and new product launches.

When Is Flexographic Printing the Better Choice?

Flexographic printing remains an excellent solution for certain applications.

It may be the right option if your business:

• Produces very high packaging volumes
• Uses the same artwork throughout the year
• Has predictable long-term demand
• Wants the lowest unit cost at very high volumes

For established products with stable demand, flexographic printing continues to offer strong value.

Why More Growing Brands Are Choosing Digital Printing

Today’s brands need more than attractive packaging.

They need agility.

Consumer preferences evolve rapidly, regulations change, product ranges expand and new marketing opportunities appear throughout the year.

Digital printing gives businesses the flexibility to respond without the delays and costs associated with traditional plate-based printing.

Whether you’re launching your first product or managing an expanding portfolio, digital printing enables you to move faster while maintaining premium print quality.

Choosing the Right Printing Partner

The best printing technology depends on your business goals, product range and expected production volumes.

At ePac Flexible Packaging, we specialise in high-quality digital flexible packaging designed to help brands innovate, grow and bring products to market faster.

From stand up pouches and rollstock to premium finishes and recyclable packaging options, our digital printing capabilities give brands the flexibility they need without compromising on quality.

Frequently Asked Questions

Is digital printing suitable for food packaging?

Yes. Digital printing is widely used for food, beverage, pet food and supplement packaging, delivering excellent print quality while supporting shorter production runs.

Does digital printing have minimum order quantities?

Digital printing allows significantly lower minimum order quantities than traditional flexographic printing, making it ideal for start-ups and growing brands.

Which printing method offers faster lead times?

Digital printing typically offers faster lead times because it does not require printing plates or lengthy setup processes before production begins.

Is flexographic printing cheaper?

For very large production volumes, flexographic printing often delivers a lower unit cost. For smaller or frequently changing orders, digital printing can offer better overall value.