Litho vs Flexo Box Printing: Which is Best for Packaging?

As you enter a store, you will notice shelves lined up with all sorts of boxes with different products. While some appear dull, others catch your eye instantly. What causes this impact? Curious to know the actual reason behind it? This effect belongs to printing, which is essential for packaging design to make it appear easily everywhere. Apart from decorative elements, printing helps customers easily recognize and differentiate the brand through its unique and distinctive identity features. In addition, high-precision printing can transform a simple box into a sophisticated and presentable one. When it comes to printing on custom packaging, there are two main types of methods that are commonly applied: litho and flexo printing.

Both printing techniques work differently and have their advantages. To know more about each type and figure out which one is better, check out our informational blog below.

The Importance of Choosing the Right Printing Method for Packaging

Given the high level of competition among brands today, there is a need for them to have packaging that will easily distinguish their products, whether they are ordinary or luxury. One approach to making this happen is by using proper printing. Colors, graphics, and properly printed logos and texts make custom box packaging more eye-catching than the boring ones. Through printing, a consumer gets an immediate sense of what the product is and which brand it belongs to.

When the printing is high-quality, boxes tend to look more appealing. They give the brand an edge over its competitors and give it an air of superiority among consumers. However, it should be noted that the approaches taken in the process depend on the materials used, styles adopted, and the budgets available.

Now, it’s a good time to discuss lithographic and flexographic printing techniques!

Flexographic Printing: How This Method Works 

Flexographic, usually termed as flexo, is a commonly used printing method. This printing process involves the ink being transferred to the box with the help of flexible plates. The plates can be of plastic or rubber. They are wrapped around the machines, rotating to provide a smooth experience for printing.

Here is the step-by-step process that the machine follows to produce high-quality printing results on different materials:

Step 1: The image or text is first raised on plates that are fixed around rotating cylinders.

Step 2: Ink is then applied evenly onto these plates.

Step 3: The cylinders start rotating during the printing process.

Step 4: As they rotate, the plates come in contact with the printing material.

Step 5: The plates press against materials like cardboard, kraft paper, cardstock, etc.

Step 6: This pressure transfers the ink from the plates onto the surface.

Step 7: The final print is created according to the required design and colors. 

Practical Applications of the Flexographic Printing Method

Flexographic printing is commonly used for shipping boxes in the e-commerce industry, such as corrugated custom foldable cartons and packaging used for deliveries. It is preferred because it is fast and keeps production costs manageable within the budget for large quantity orders.

It is also widely used for food packaging, like pizza boxes, cereal boxes, and kraft paper bags. These products usually have simple designs and are made from recycled or eco-friendly materials, which makes flexo printing a practical option for sustainable packaging.

Pros and Cons of the Flexographic Printing Technique

Just as the flexographic method offers many benefits, it also has some drawbacks. The following is a comparison table of some of its main pros and cons.

Now that we have gotten an overview of what flexographic printing is, its working method, applications and its pros and cons, let's move towards lithographic printing and see what it offers. 

Lithographic Printing: Understanding How It Works 

Lithographic printing (litho print) is a method that uses flat plates instead of raised surfaces. It works on the idea that oil and water do not mix. In this method, images, graphics, and text are printed clearly on paper. In packaging, these printed sheets are often laminated onto rigid boxes or corrugated material. 

This method is more complicated than flexographic printing, but it gives neat and high-quality results, especially for detailed designs. Now, let's see the working of this printing technique. 

The following is the process explained step by step, showing how lithographic printing is done on different types of materials.

Step 1: Preparation of Plates

The design is first made on a flat metal plate, which is usually aluminum or limestone. The plate is prepared so the image areas can hold ink properly.

Step 2: Water Applications 

Water is applied to the plate. It stays only in the non-design areas. These wet areas push the ink away, so only the design part takes the ink and prints clearly.

Step 3: Inking of Plates 

Ink is rolled over the plate. It sticks only to the design areas, while the wet parts keep the ink away.

Step 4: Transfer to Blanket

The inked design is then moved from the plate onto a soft rubber blanket.

Step 5: Transfer of Design to Packaging Material

The rubber blanket presses the image onto paper or another printing material.

Step 6: Final Result

Pressure is applied so the print becomes clear, sharp, and of good quality to achieve premium printing packaging. 

Common Applications of Lithographic Printing

Lithographic printing is commonly used for premium packaging such as cosmetic boxes, perfume boxes, and luxury retail packaging. It is preferred because it produces sharp images, rich colors, and a high-quality finish. 

It is also used for gift boxes, rigid boxes, and high-end product packaging, where visual appearance plays an important role in improving product presentation and brand perception.

Pros of Lithographic Printing 

Here are the key advantages of lithographic printing that show why it is widely used for high-quality printing work.

1. High-Quality Printing

When it comes to producing clear and sharp results, lithographic printing does the job well. It is good for fine details, small text, and bright color output.

2. Budget-friendly for Bulk Printing

It offers cost-effectiveness when you opt to print large quantities. This makes it a good option for the mass production of packaging boxes.

3. Can Be Used for Many Materials

This method is not only for packaging. It is also used for flyers, brochures, leaflets, and other printed materials.

4. Good for Product Appearance

It helps products look more attractive and premium by giving clean graphics and logo printing.

5. Supports Many Colors

It allows the use of a wide range of colors, which makes the final print look more vibrant and eye-catching.

Cons of Lithographic Printing

The following are the main drawbacks of lithographic printing that should be considered before choosing this method.

1. Expensive Method

Lithographic printing tends to be more costly than flexographic printing. It is because it requires more setup materials alongside the plate-making. 

2. Time Consumption 

It consumes more time, especially when you are doing large print runs. It is because the setup process takes time. 

3. Not Ideal for Rough Surfaces

It does not work well on rough materials and is mainly suitable for smooth or laminated surfaces for better print quality.

Flexographic vs Lithographic Printing: A Brief Comparison

How to Decide Between Flexographic and Lithographic Printing for Your Packaging Needs

When Flexo Printing is the Better Choice

• Flexo is a good option when you need a large number of boxes in a short time and at a low cost.
• It is useful when you want affordable printing for bulk packaging production.
• It works well on rough materials like kraft paper and corrugated sheets used for shipping boxes.

When Litho Printing is the Good Choice

• Litho is better when you want high-quality packaging with a smooth and sharp finish.

• It is ideal for designs that include detailed images, graphics, and multiple colors.

• It is a good choice when you want your packaging to look premium and attractive.

• It is commonly used for luxury packaging like gift boxes, jewelry boxes, and rigid boxes.

Final Thoughts! 

The choice of printing technique, either flexographic or lithographic, depends on the requirements of your packaging. If you are opting for simpler designs for your custom boxes and need them in large quantities, then flexo printing is a reliable option. It is quick and budget-friendly, as well as works quite well on rough materials like custom corrugated boxes, etc.

However, if you want to design your custom luxury boxes with high print quality and very fine details, then litho printing is the better method to work with. It produces crisp images and works ideally with smooth or laminated surfaces. It also works with precise color combinations, delivering a sleek finish to your high-end products. 

In the end, the best printing option solely comes down to your design details, the type of material you are using, your budget, and how quickly you need your custom printed boxes. The right method will help you get the best results!