In the world of packaging, the sheer number of choices can sometimes feel overwhelming. Between flexo, litho, and digital options, the terminology alone is enough to make a packaging buyer pause. At Pratt Industries, we believe your packaging supply chain should be a competitive advantage, not a point of stress.
We view ourselves as your partner in this journey. Whether you are launching a seasonal promotion or managing a high-volume steady-state product, understanding the "how" behind the print can help you save money, reduce waste, and get to market faster.
Matching the Method to the Mission
Pratt offers a comprehensive portfolio of print solutions because we know one size rarely fits all. Here is a quick guide to help you navigate the options available across our national network:
- Flexography (Flexo) Direct Print: This is the workhorse of the industry. It involves printing directly onto the corrugated sheet. It is perfect for industrial applications or high-volume runs with relatively simple print where 1-4 colors are sufficient. It is cost-effective and reliable.
- High-End Direct Print: When you need a bit more "pop,” higher quality graphics printed on a glossy substrate, this method offers better resolution (up to 85 lines per inch) and allows for up to 7 colors plus varnish. Relative to litho, it is more cost effective for medium length volumes that allow you to amortize the print plate costs which can range from $10 to $15 thousand per plate set depending on the number of colors. It’s a good middle-ground for brands needing higher visibility without moving to lithography.
- Flexo Pre-Print. If you're aiming for mass production, especially for high-moving consumer goods packaging, Flexo Pre-Print is the usual choice. This process involves printing the paper rolls before they even become corrugated, using huge presses that can run faster than 1,000 feet per minute. This kind of speed, plus the great print quality, makes it the most cost effective option for really big runs. However, things to consider: high plate costs; large minimum order quantities (MOQs) and longer lead times.
- Offset Lithography (Litho): For years, this has been the gold standard for premium packaging. It involves printing on a separate sheet of paper. Depending on the order quantities, the sheet of paper may be a label which is then laminated, or glued, to the finished corrugated board. Larger order quantities use a method called single face lamination (SFL), where a litho printed top sheet is laminated directly to the corrugated single face (the bottom and middle layer of the corrugated board). Litho offers photo-realistic imagery and superior ink ranges, making it ideal for retail-ready packaging and club store displays.
- Digital Direct to Corrugate: The process prints digital images directly to the paper substrate using industrial inkjet technology. Instead of using physical printing plates, the printer "sprays" the design straight onto the sheet. This makes it faster and more flexible than traditional methods. This is an emerging technology that offers an alternative to litho lamination, where print quality is comparable but digital direct usually has lower lead times and lower MOQs. Ideal for point of purchase display and small emerging brands using e-commerce as their primary distribution channel.
- Digital Pre-Print: This is where the future meets the present. Combining litho-like quality with the productivity of flexo pre-print. This technology requires no print plates and tends to have lower MOQs. It allows for incredible speed and the flexibility to change artwork between runs—perfect for seasonal rollouts or targeted regional campaigns. This method is recommended if you are worried about obsolescence risk, and want to manage a lean supply chain.
The Pratt Difference: Agility and Sustainability
What makes Pratt unique isn't just that we have these technologies; it's how we use them. We are committed to providing innovative, custom solutions that help you win in the marketplace.
Because we are vertically integrated, we can offer unbiased advice on which process suits your specific budget and timeline. And perhaps most importantly, we do all of this while staying true to our core mission. Whether you choose a simple brown shipping box or a high-graphic retail display, you are utilizing sustainable corrugated material including 100% recycled paper from Pratt’s 100% recycled paper mills.
Next Steps: Not sure which print method is right for your next project? Reach out to your local Pratt sales representative today. Let’s sit down and build a solution that works for your brand and your bottom line.