When is it better to choose flexographic printing over digital printing for paper bags?

It’s best to choose flexographic printing over digital printing for paper bags when the order quantity is large, a wider color palette is desired for the bag’s appearance, or the print needs to extend to the sides and bottom of the bag. However, the printing method is not freely selectable by the customer: it is determined based on the order quantity. The following sections explain what flexographic printing entails in practice and what types of needs it is best suited for.

What is the difference between flexographic printing and digital printing on paper bags?

Flexographic printing and digital printing differ from one another in terms of technology, print area, and color profile. Flexographic printing is an industrial process suitable for larger orders and allows for printing not only on the front and back of the bag but also on the sides and bottom. Digital printing, on the other hand, is a faster option suitable for smaller orders, with a print area limited to the front and back of the bag.

The two methods differ significantly in terms of color profiles. Digital printing uses the CMYK color profile. Flexographic printing also uses the PANTONE color profile, which ensures precise, standardized color shades.

In addition, flexographic printing allows the entire surface of the bag to be colored—for example, creating a yellow bag or black handles—which cannot be achieved in the same way with digital printing. These differences make the methods complementary rather than competitive.

When is flexographic printing a more cost-effective option?

Flexographic printing becomes a cost-effective option for larger print runs, as the costs of printing plates and production set-up are spread across a greater number of jobs. The larger the print run, the lower the unit cost. For smaller orders, digital printing is typically the more economical choice, as it does not involve the same set-up costs.

In practice, this means that flexo printing is best suited to situations where bags are required on a regular basis. For retail chains, distribution companies or other organisations with a continuous need for paper bags printed with their logo, flexo printing is often the natural choice.

It is also worth noting that lead times for flexographic printing are longer than for digital printing. This should be taken into account when scheduling orders, particularly if the bags are needed quickly for a campaign or peak season.

Is flexographic printing suitable for all paper bag designs and materials?

Flexographic printing is suitable for a wide range of paper bag styles, but not equally so for all of them. The method works particularly well for flat-handled and drawstring paper bags, and it also allows for printing on the sides and bottom of the bag, which is a clear advantage over digital printing.

Printing options should be evaluated on a case-by-case basis, as the bag’s structure and material affect how well the printing turns out in practice. Flexographic printing can also be used to change the entire base color of the bag, which opens up possibilities for implementing brand colors in a way that digital printing cannot.

How does the order quantity affect the choice of printing method?

In practice, the order quantity is the factor that determines which method is used. The customer does not choose the printing method; rather, it is determined based on the order quantity. Smaller orders, starting at 100 copies, are produced using digital printing. Larger orders are produced using flexographic printing.

This distinction is practical: digital printing is well-suited for small businesses or one-off campaigns that require flexibility and speed. Flexographic printing, on the other hand, serves businesses with a continuous or high demand for logo-printed bags and for whom color accuracy and a larger print area are important.

As order quantities increase, the unit price of flexographic printing decreases, while also opening up the possibility for more extensive visual design, such as printing on the sides and bottom of the bag and changing the color of the entire bag.

Is flexographic printing the right choice from an environmental perspective?

Environmental considerations alone are not a reason to choose flexographic printing over digital printing, and neither method is automatically more sustainable than the other. What matters more is choosing paper bags over single-use alternatives and ensuring that the bags are reused.

If you’d like to find out which printing method best suits your needs, please contact us via the contact form and let us know your order quantity and preferences. Kassatieto’s experts will help you find the best solution.

Kassatieto is a second-generation Finnish family business that combines extensive experience, Finnish production and responsible business practices. Our aim is to make our customers’ daily lives run more smoothly with reliable products and expert service.