Flexographic printing in packaging: a buyer’s guide

If you’re responsible for buying packaging, you’re likely under constant pressure to deliver on multiple fronts:

• Control costs, even when material prices shift.
  
• Hit tight deadlines without compromising quality.
  
• Ensure every pack meets sustainability requirements.
  
• Make the product stand out on the shelf — and keep it that way through logistics.
  

We see these challenges every day. Between our production floor and client meetings, we know exactly how critical it is to choose a printing method that supports all of these goals.

That’s why, for many of our clients, flexographic printing has become the go-to solution.
It’s not a magic fix for everything, but when the product and run size are right, flexo offers a unique balance of cost efficiency, high print quality, sustainability, and speed.

In this guide, we’ll walk you through how flexo printing solves real buyer problems, drawing on our hands-on experience with presses ranging from 250 mm to 1,400 mm wide — allowing us to handle everything from narrow-label runs to large-format flexible packaging.

1. Controlling costs without sacrificing quality

Buyer challenge: Your packaging budget is fixed, but marketing still expects vibrant, precise designs.

How flexo helps: Flexo uses cost-effective, fast-drying inks (including water-based options) and efficient setups. This means you can run large or medium orders without the high per-unit cost often seen in other methods. Plate costs are spread over the run, and once set up, production is highly efficient.

Example: For a snack brand launching seasonal packaging, we ran 350 mm wide rolls on one of our mid-width presses — balancing material use and print speed to hit both cost and visual targets.

2. Versatility across materials

Buyer challenge: You source multiple packaging formats — labels, pouches, paper wraps — and don’t want to juggle multiple print suppliers.

How flexo helps:
Flexo can print on a broad range of substrates:

• Paper and heat-sealable papers
  
• Plastic films
  
• Laminates and foils
  
• Barrier-coated recyclable materials
  

With our press range from 250 mm to 1,400 mm, we can handle everything from small artisan labels to wide flexible rolls for automated packing lines.

3. Meeting sustainability goals and compliance

Buyer challenge: Regulations and brand commitments demand eco-friendly packaging without losing performance.

How flexo helps:

• Water-based inks with low VOC emissions
  
• Recyclable monomaterials that meet EU 2030 recyclability rules
  
• Certified compostable structures for specific product types
  
• Barrier coatings that enhance protection without compromising recyclability or compostability
  

We’ve helped tea brands switch from PE-laminated paper to heat-sealable recyclable paper, and cereal producers reduce their Extended Producer Responsibility (EPR) fees by moving to compliant recyclable structures.

4. Speed and consistency for time-sensitive launches

Buyer challenge: Marketing confirms the design late — but the launch date doesn’t move.

How flexo helps: Flexo presses can run at high speeds, with stable colour management, meaning that once the plates are ready, we can move fast without sacrificing consistency.
Our hybrid prepress workflow and in-house plate production keep lead times short, whether we’re running a 500 mm mid-web job or a full 1,400 mm wide flexible film roll.

5. High-quality results that reflect your brand

Buyer challenge: Poor print quality can damage brand perception instantly.

How flexo helps: Modern flexo achieves fine-line detail, photographic images, and solid, vibrant colours. Our colour management and proofing systems ensure your design translates perfectly from screen to substrate — batch after batch.

Checklist for packaging buyers considering flexo

Before you choose flexo printing for your next packaging project, ask:

1. Is my packaging substrate compatible with flexo?
   
2. What is the ideal roll width for efficiency?
   
3. Do I need barrier coatings for shelf life?
   
4. Are my sustainability goals met with this material/ink choice?
   
5. Is my run size balanced for cost-efficiency?
   

Final thoughts

We believe that good packaging printing isn’t just about technology — it’s about aligning production capabilities with buyer needs.

With flexo, we can deliver on cost, quality, and sustainability, whether you need narrow labels, mid-width runs, or large-format flexible rolls.

If you’re weighing your options, our production and account management team can guide you through material choice, print setup, and sustainability compliance — so your packaging is ready for both today’s market and tomorrow’s regulations.

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