Types of Printing on Corrugated Boxes

Printed corrugated boxes protect products while also acting as ambassadors, proudly showcasing the brand messaging and product benefits. Different types of printing options are available, so how do you know which is best for your business? 

Each printing option has pros and cons that are better suited to different businesses depending on the order volume, budget and design complexity. Read on to find the perfect printing type for your corrugated cardboard boxes. 

What Is Corrugated Cardboard? 

Corrugated cardboard is a multilayer material made of thick paper stock or heavy paper pulp. The corrugated layer is known as the flute, and it’s arranged in different patterns to help it hold its shape better. It’s strong and durable, making it bump-resistant and keeping it intact during rough transits. Four main types of corrugated cardboard are used in packaging: 

Single face board: This type of corrugated cardboard has a one-layer board with a medium flute. It’s typically used to cushion products that are set in a larger container. 
Single wall corrugated board: This is the most common style of corrugated boxes. Printing on this type of corrugated cardboard often renders flawless results.
Double wall board: This board style has two fluted mediums and three liner boards, offering higher durability. These boards are perfect for heavy or fragile products. 
Triple wall board: Boxes made from triple wall board offer unmatched durability and are typically used for highly sensitive items.

Types of Printing Methods for Corrugated Boxes

Different designs, uses and colors call for specific methods. It’s important to understand the types of printing on corrugated boxes to make the best choice. Here are the three common methods for printing on corrugated boxes: 

Flexographic Printing 

Flexographic printing uses flexible rubber plates that are mounted on a cylinder to create an impression on the material. This process enables the machine to deliver quality prints in high volume using a wide range of inks. Flexographic printing is ideal for corrugated carton printing with simple designs.

Pros: 

Provides cost-effective prints for bulk runs 
Offers quick setup for tight deadlines 
Works well for simple or minimalistic designs 

Cons:

Offers limited color options 
Reduces the clarity of intricate designs

Lithographic Printing 

Lithographic printing, also known as litho printing, is a popular process for printed corrugated cardboard. It’s used for printing vibrant graphics on product boxes that need to stand out in high-traffic areas. Typically, the process involves placing the desired artwork on a plate covered in ink, and the material positioned on the image rapidly absorbs the ink. This process is known as offset printing. 

Pros: 

Offers versatility for a variety of formats, from magazines to product packaging 
Delivers quick, high-quality prints of repeat items
Provides high resolution and clarity, making it ideal for complex graphics

Cons:

Can be more expensive than flexography 
May require additional laminating runs 
May have limited sizing options for unusual box sizes

Digital Printing

Digital printing is a direct-to-surface technique that’s the preferred method for cardboard and coated boxes. It reproduces electronic images onto the desired material. Unlike the other printing methods that call for plates and other steps, digital printing uses technology like laser or inkjet to print directly from digital files. 

Pros: 

Creates vibrant, high-resolution images 
Makes revisions easier to master, allowing for highly customizable prints 
Provides the perfect option for short runs 
Removes the need for extra formatting materials and prepressing

Cons: 

Typically more costly for high runs 

Direct Printing vs. Pre-Printing

Direct printing is printing directly onto the corrugated box, while pre-printing involves printing onto a separate material and then applying it to the box. If you’re trying to decide how to print on corrugated boxes, here’s a table to make the process easier: 

Factors to Consider When Choosing a Printing Method

Corrugated boxes are a crucial part of brand image, and it’s important to choose the printing method wisely. Here are the top factors to consider when deciding: 

Cost

Flexographic printing is the most cost-effective method. It prints directly on the box and only calls for a one-time investment in print plates. 

Flexographic printing can process up to 12,000 sheets per hour and create high-quality images. It’s typically used for subscription, bakery and shipping boxes. 

Quality and Resolution

If you need high-detail images, then lithographic or digital printing may render the best results. Flexographic prints can also provide vibrant images for minimalist designs. Choose a print method that can create your desired image quality. 

Turnaround Time

How quickly do you need the boxes? If speed is one of the most crucial factors, choose a method that allows for quick, high-quality graphics, like flexographic printing. Businesses offering personalized prints should choose an option that can make speedy revisions, like digital printing. 

Volume

If you’re looking for short-run prints, digital printing might be a good option. For high-volume projects, flexographic printing is a better option. You should also consider the product volume, dimensions and weight when deciding on a printing method. 

Bigger packaging would be a better match for direct printing methods, as they have a larger surface area. It would cost more for laminating and have much longer lead times. 

Color Options

Corrugated carton printing offers many opportunities for creativity. Flexographic methods allow for three-color printing, while lithographic printing accommodates up to six colors. Generally, digital printing offers a wider color variety, making it an excellent choice for super colorful artwork. 

Design Complexity

Simple designs call for fewer colors, which can make them suitable for more cost-effective methods like flexographic printing. More complex designs call for methods like digital printing. 

Additionally, consider if there are any legal requirements that would call for warnings, barcodes or nutritional information. In these cases, choose printing methods that create highly detailed images for maximum visibility. 

Intended Use

Do you plan to create product packaging for retail use or shipping boxes? Retail packaging needs to be eye-catching to draw shoppers’ attention. Shipping boxes also need to be visually appealing, but they should also be ultra-durable to withstand rough transit conditions. 

Working With a Box Manufacturing Company

Finding a reputable box manufacturing company involves aligning your business vision with a supplier that can bring it to life. Here are the top factors to consider when making a choice: 

Do they have years of experience creating the kind of packaging designs you’re interested in? 
Does the quote align with your budget? 
Do they use sustainable packaging materials? 
What certifications do they have?
What box options do they offer, and are they customizable? 

Get Printed Corrugated Boxes That Stand Out

At Bolt Boxes, we know how to print on cardboard boxes, but it goes beyond that — we know how to make an impact through custom packaging. We have over 60 years in the packaging business, and our expertise shows in our 99% on-time success rate and our raving testimonials from satisfied clients. We are ISO 9001:2015- and G7-certified and offer unmatched customer service. 

Our custom boxes are made from 100% recyclable corrugated cardboard, offering you packaging that protects your products and the environment. As the fastest box manufacturer in the world, we have no doubt that we can help you meet your deadlines. 

Do you want to increase positive brand perception through high-quality, durable and visually appealing packaging? Contact us today for packaging that ticks all the boxes.