Best Printing Methods for Packaging in 2025 | Guide for Brands

Author | Date: 07/08/2025

Why Printing Still Matters in the Digital Age?

Despite digital media dominance, printing remains the tactile heart of product branding, packaging, and real-world marketing. In fact:

The global printing market was valued at over £350B in 2023.
70% of businesses say printed materials boost trust and visibility.
25% of operations now include eco-friendly print processes.

From product boxes to retail displays, printing methods play a key role in how your brand is seen, touched, and remembered.

Digital Printing: Fast, Custom, and Sustainable

What is it? Digital printing transfers artwork directly from a digital file onto the substrate (paper, card, or label stock), skipping the plate setup.

Best For:

Small batches or personalised designs
Brands needing fast turnarounds

Pros:

Lower setup cost and less waste
Great for variable data (e.g., barcodes, names)
Eco-friendly inks and substrates available

Cons:

Higher per-unit cost for large runs
Colour matching not always perfect

Use Cases:

Event menus, direct mail, custom cosmetic boxes

Offset Lithography: Bulk with Beauty

What is it? Offset printing uses plates to transfer ink to a rubber blanket, then onto paper or board. Known for vibrant, consistent output.

Best For:

Bulk packaging
Marketing brochures, magazines

Pros:

Economical for long runs
Consistent, sharp imagery

Cons:

Not ideal for short runs
Longer setup times

Use Cases:

Corrugated retail boxes, catalogues, corporate stationery

Screen Printing: Bold and Durable

What is it? Ink is pushed through a mesh screen stencil to print onto surfaces. Often used for textiles and promotional goods.

Best For:

Branded merch (shirts, bags)
Signage and product displays

Pros:

Vibrant colours, long-lasting
Great on wood, glass, metal, fabric

Cons:

Expensive setup for low-volume orders
Slower than digital for complex jobs

Use Cases:

Branded t-shirts, POS signage, promotional mugs

Flexography: Built for Speed & Packaging

What is it? Flexo printing uses flexible plates and quick-dry inks to print on rough or curved surfaces.

Best For:

Packaging, especially food-grade
Labels, shrink sleeves, films

Pros:

Fast throughput
Works on various substrates (cardboard, plastic)

Cons:

Less sharp on fine details
Plate production cost

Use Cases:

Snack boxes, drink labels, corrugated trays

Gravure Printing: High-End Volume

What is it? Designs are engraved onto cylinders. Ink fills the engraved cells and is transferred to substrate.

Best For:

High-volume, luxury packaging

Pros:

Sharp details and vivid tones
Consistent results over long runs

Cons:

High initial investment
Not economical for small batches

Use Cases:

Magazines, premium box wraps, foil packaging

Large Format Printing: Big, Bold, Brilliant

What is it? Used to produce graphics on oversized materials for events or advertising.

Best For:

Trade shows, storefronts, vehicle wraps

Pros:

High visibility and resolution
Wide material compatibility

Cons:

Slower print speed
Requires protective coatings for outdoor use

Use Cases:

Exhibition banners, outdoor ads, in-store displays

3D Printing: Precision in Prototyping

What is it? Creates objects layer-by-layer from CAD files, mostly for prototypes or custom parts.

Best For:

Product development
Custom parts, short-run samples

Pros:

Low waste
Complex shapes with no tooling

Cons:

Slow output
Costly for mass production

Use Cases:

Packaging prototypes, medical devices, product mockups

Thermal Printing: Efficient for Logistics

What is it? Uses heat-sensitive paper to create prints. Mostly black-and-white.

Best For:

Labels, shipping tags, point-of-sale

Pros:

Fast and inexpensive
Compact machinery

Cons:

Limited colour
Image fades over time

Use Cases:

Barcode stickers, shipping labels, retail receipts

Letterpress: Old-School Elegance

What is it? Applies pressure to transfer ink from raised metal type. Rare but beautiful.

Best For:

High-end, tactile prints

Use Cases:

Wedding invites, premium business cards

Sustainability in Printing

Recycled stocks, soy-based inks, and waterless processes are on the rise.
Digital and flexo methods often align best with green goals.
Clients increasingly request FSC-certified or carbon-neutral options.

How to Choose the Right Method?

Ask yourself:

What volume do I need? (Short = digital; Bulk = offset/flexo)
What substrate am I using? (Rough = flexo; smooth = offset)
Do I need personalisation or prototyping? (Yes = digital or 3D)
Is sustainability a goal? (Flexo, digital, and eco-certified options work best)

Contact Our Team for Expert Advice

Wondering which printing method will truly do your packaging justice? Let’s talk. At Buy Packaging Boxes, we’ll help you find the perfect match for your product, your brand, and your budget.

Explore Our Custom Printed Packaging ➔

FAQs: Real Questions from Brands Like Yours

What is the most cost-effective printing method for bulk orders?

Offset or flexo printing is most economical for high volumes due to low per-unit costs.

Which printing method is best for personalised packaging?

Digital printing offers easy customisation and fast setup for small batches.

Are eco-friendly printing options available?

Yes! Waterless printing, soy inks, and recycled boards are increasingly available.

Can I use multiple printing methods on one product?

Yes—many premium boxes use a mix (e.g., offset + foil stamping).

Which method gives the sharpest detail?

Gravure and offset printing produce the highest-definition images.

Best Printing Methods for Packaging in 2025 | Guide for Brands

Table of Contents

Why Printing Still Matters in the Digital Age?

Digital Printing: Fast, Custom, and Sustainable

Offset Lithography: Bulk with Beauty

Screen Printing: Bold and Durable

Flexography: Built for Speed & Packaging

Gravure Printing: High-End Volume

Large Format Printing: Big, Bold, Brilliant

3D Printing: Precision in Prototyping

Thermal Printing: Efficient for Logistics

Letterpress: Old-School Elegance

Sustainability in Printing

How to Choose the Right Method?

Contact Our Team for Expert Advice

FAQs: Real Questions from Brands Like Yours