Digital printing (inkjet/toner) outputs directly from files with no plates, making it ideal for low MOQs, fast turns, many SKUs, and on-demand packaging.
When to choose digital
Low volumes: 10–1000 pcs without plate costs
Speed: samples or short runs in 1–5 days
Variants & personalization: names, barcodes/QR, languages, A/B tests
Frequent updates: pilot launches, seasonal promos, limited editions
Suitable formats
Folding cartons: STE/RTE tuck, crash-lock, sleeves
Mailer/corrugated boxes: E/B-flute (direct inkjet or litho-lam)
Labels & stickers: roll or sheet, with spot varnish/cold foil options
Soft-pack mockups: artwork validation before flexo/gravure scale
Collateral: belly bands, inserts, manuals
Key advantages
No plate/setup cost → best unit economics at small runs
On-demand production → reduce obsolescence & inventory risk
Flexible color management → ICC workflows for brand consistency
Variable data printing → true mass customization
Limitations & workarounds
Unit cost at large runs: beyond ~3–5k pcs, compare with offset/flexo
Metallics/fluorescents: need capable engines or simulate via finishing (foil, spot UV)
Durability: recommend lamination (matte/gloss/anti-scuff) or AQ/UV coats
Substrate compatibility: some films need primers or Indigo/UV-inkjet grades
Materials & finishes (typical)
Boards: SBS/FBB 250–450 gsm; test specialty stocks first
Corrugated: white E/B-flute (direct digital or laminated)
Labels: paper/PP/PET, roll or sheet
Finishes: matte/gloss/soft-touch/anti-scuff lamination, spot UV, foil, emboss/deboss
Proofing & color
Digital proof → structural white mockup → press sample
Provide Pantone/LAB targets; maintain device curves/ICC; keep stock consistent for repeatability
Design & workflow tips
Use L × W × H (internal); mind grain direction and crease rules
Laminate dark solids for scuff resistance; reinforce window cut lines
For VDP, supply a CSV/Excel and layout rules (fonts, placement)
Prefer water-based coatings, solvent-free glues, and mono-material builds for recycling
Lead times & MOQ (typical)
MOQ: starts from ~100 pcs (lower possible at higher unit cost)
Samples: 1–3 days; short-run production 3–7 days (holidays extend)
Use cases
Pilot launches/crowdfunding, seasonal drops
Retailer-specific SKUs/barcodes, regional languages
Personalized gift sets and corporate kits
Takeaway: Digital is the fastest, lowest-risk route for small batches and high SKU agility. As volumes grow, consider hybrid strategies with offset/flexo for best total cost.