Corrugated box printing methods explained

Why the print method matters

The way a box is printed affects far more than how it looks. It shapes unit cost, set-up charges, minimum order quantities, lead times and how easily artwork can change. Choosing the right method means matching print quality to the value of the product, the size of the run and the job the box has to do.

Flexographic printing (flexo)

Flexo is the most widely used method for corrugated. Ink is transferred directly onto the board from flexible rubber or photopolymer plates mounted on rotating cylinders.

• Best for: high-volume transit cartons, shipping boxes and secondary packaging
• Strengths: fast, cost-effective at volume, low unit cost once plates are made
• Watch-outs: plate costs for each design; fine detail and colour vibrancy are more limited, especially on brown kraft board

Litho-lamination

With litho-lamination, artwork is printed lithographically on a separate high-quality paper sheet, which is then laminated onto the corrugated board.

• Best for: premium retail packaging, display and presentation boxes
• Strengths: high resolution, vibrant colour and photographic images, with the structural strength of corrugated underneath
• Watch-outs: the extra lamination step adds cost and lead time

Digital printing

Digital printing applies artwork straight from a digital file, typically using inkjet technology, with no printing plates required.

• Best for: short runs, prototypes, seasonal or regional variants and personalised packaging
• Strengths: no plate costs, quick artwork changes, high-quality results on smaller quantities
• Watch-outs: unit cost is usually higher than flexo on long runs

Gravure printing

Gravure uses an engraved metal cylinder to carry ink to the substrate. In corrugated, it is mainly used to pre-print liner paper before it is made into board.

• Best for: very long runs where consistent, high-quality graphics are needed
• Strengths: excellent, durable image quality and consistency across huge volumes
• Watch-outs: high cylinder and set-up costs make it impractical for short runs or frequent artwork changes

Screen printing

Screen printing pushes ink through a stencil mesh, one colour layer at a time.

• Best for: small quantities and simple, bold designs
• Strengths: strong, opaque colour
• Watch-outs: slow and labour-intensive, so rarely used for large-scale corrugated production

Pre-print, post-print and lamination

Alongside the printing method, there are three broad points in the process where print can be applied:

• Pre-print: graphics are printed onto reels of liner paper before the board is corrugated. This gives good colour control and sharp detail, suited to long runs.
• Post-print (direct print): ink is applied to the finished corrugated board, usually by flexo. It is the fastest and most economical route for most transit packaging.
• Lamination: a separately printed sheet is bonded to the board, giving a premium finish while keeping the board’s strength.

At a glance

Choosing the right method

• High volumes and simple designs: flexo
• Premium, detailed retail packaging: litho-lamination
• Short runs, versioning or personalisation: digital
• Very long runs with fine detail: gravure pre-print
• Small batches of bold designs: screen

For buyers, the most useful question is not simply “which looks best?” but what the box needs to achieve. A shipping carton seen only in a warehouse rarely justifies litho-lamination, while a retail-ready pack on shelf may earn its cost back. Look at total cost across set-up, plates, unit price and stock-holding, and review whether artwork variants could be consolidated or moved to digital.