To flexo print or digital print—that is the question. The answer, like many things in life, is “it depends.”
As a professional custom label converter, General Data offers expertise in both types of label printing processes, and we’re here to help you understand the key differences so you can guide your customers toward the perfect labeling solution for their needs.
Let’s dive into the differences between digital label printing and flexographic (or “flexo”) label printing and the most practical applications for each technique.
Digital label printing involves using digital art files and static or variable data from a computer to directly print on a substrate using inkjet or toner-based printing technology. Digitally-printed custom labels feature high resolution, sharp text and vibrant colors that can rival traditional printing methods. Because no printing plates are required, it allows for faster setup and more flexibility in design changes and incorporating variable design elements, information and personalization.
Pros of Digital Label Printing
Because it’s easy to create and modify label designs and information digitally without the need for plates, digitally printed labels can be a nimble, cost-effective option for printing custom labels in smaller quantities. However, digital color label printing now has advanced capabilities that enable it to go beyond just being a solution for short runs. These include:
- Variable, randomized and personalized content
- Hyper-customization
- Anti-counterfeiting and brand protection
- Prototyping and sample production
These types of labels can include variable data such as different designs, colors, logos and information without the need to switch out plates, and minimal setup makes for a faster turnaround time. At General Data, our digital printed labels can even be finished with spot varnishes and custom die-cutting.
Plus, you can specify the exact quantity, so there’s less overall waste - a benefit from both a cost and environmental standpoint.
Cons of Digital Label Printing
While digital printing is a great choice for short label runs, it doesn’t scale as well for high-volume label production. Some digital inks or toners may also not be as resistant to abrasion, sunlight or moisture. Additionally, depending on the digital printing technology or press used, spot color matching may also not be as precise as with flexo printing, an important consideration for brands that require strict color consistency.
Ideal for short to medium runs, digital printing works well in applications such as:
- Product labels for craft food and beverage products
- Pharmaceutical and medical labels
- Short-run promotional labels and packaging
- Prototype or seasonal designs
- Labels with variable data, colors, or design elements
Read more about digital label printing opportunities in our previous blog post.
Flexographic printing, or flexo printing, does not require a digital component. Instead, it is a high-speed, high-volume printing method that uses flexible photopolymer plates wrapped around cylinders containing the raised design of the artwork, along with anilox rolls to transfer ink to the plate. The plates then transfer the ink on to the surface of a substrate moving through the press. It is a versatile and efficient process for printing labels, packaging, and other items on roll materials such as paper and plastic film.
Pros of Flexo Label Printing
With the ability to run continuously at high speeds, flexo label printing is a highly efficient process for producing large runs of printed custom labels at low cost. It can print on a wide range of substrates, including paper and films such as BOPP, PET and PE. It also allows other printing and finishing processes to be completed in-line, including spot and pattern coatings, laminating, embossing and foil stamping.
Cons of Flexo Label Printing
While there’s no doubt that flexo printing produces a high-quality product, it is not cost-effective for short runs due to the longer and more involved set up required. When multiple designs, color changes, or changes to other printed information is required, changing out plates or inks is much more time-consuming. Flexo printing can also generate more material waste during setup and calibration.
Flexo is a popular and cost-effective choice for printing on a wide variety of different label stocks, from paper to the most durable film-based substrates. Many embellishments can be added to flexo-printed labels in-line on press, including spot and pattern varnishes and coatings, laminates, foils, and embossing.
Flexo printing also provides the best value for large label runs due to its speed and printing efficiency.
- A wide variety of pressure-sensitive labels and tags
- Flexible and shrink-sleeve packaging
- Packaging for food, beverage, pharmaceutical and consumer products
- Industrial and chemical labels and packaging