What are the differences between digital printing and flexo?

Digital printing and flexo printing are two different printing methods with distinct characteristics. The technology involved is the overarching distinction between the two. Digital printing involves directly transferring the digital image or design onto the printing substrate using a digital file, using inkjet or laser technology to apply ink onto the surface. Flexo printing (short for flexographic printing) utilizes flexible relief plates made of rubber or photopolymer to transfer ink onto the printing substrate.

Here is an overview of the primary differences between the two:

Setup and Plate Making

Digital printing does not require the creation of plates. The digital file is sent directly to the printer, eliminating the need for complex setup and plate-making processes.

Flexo printing involves the creation of custom plates. The plates are prepared by etching the image onto the plate material which can be time-consuming and requires skilled labor, typically resulting in an associated setup cost.

Print Quality and Color Accuracy

Digital printing can be limited when it comes to print quality and color accuracy. While it is suitable for short to medium print runs, slight variations in color may arise for longer runs. Additionally, CMYK is the current model used in digital printing, so the number of possible color combinations is limited as there are only 4 process colors.

Flexo printing provides excellent print quality with additional perks like lamination, varnishing, cold coil, and more. Additionally, our flexo label printing offers 12-color processing, allowing us to achieve virtually any outcome with premium color-matching capabilities. It is more suitable for large print runs where slight variations in color may be acceptable.

Substrate Compatibility

Digital printing can be used on a wide range of substrates, including paper, cardstock, plastics, fabric, etc. It offers great flexibility in terms of the materials it can print on.

Flexo printing is commonly used for printing on flexible packaging materials such as paper, plastic films, labels, and corrugated board. It is well-suited for packaging applications.

Cost and Efficiency

Digital printing is cost-effective for short to medium print runs because it eliminates the need for plate making and setup costs. It is highly efficient for various print jobs and has a fast turnaround time.

Flexo printing can be more cost-effective for extremely large print runs due to the lower cost of the plates and faster production speeds. However, it may involve high setup costs and longer turnaround times.