Production
Flexo, Offset and Digital Printing: A Packaging Cost Comparison
One-off and per-unit costs of flexo, offset and digital printing in packaging — which is economical at which quantity and colour count?
For the same box, flexo, offset and digital printing can give wildly different prices — and there's no fixed answer for "the cheapest method." The right method shifts at the intersection of quantity, colour count and quality expectation. In this article we compare the cost logic of the three methods.
- Digital has no one-off cost but a high per-unit cost; it wins at low volume.
- Flexo is cheapest at high volume + few colours; plate cost melts as it spreads across units.
- Offset offers high quality/detail but a high plate cost; preferred for coated-carton work.
The cost structure of the three methods
| Method | One-off | Per unit | Quality |
|---|---|---|---|
| Digital | None / very low | High | High (short runs) |
| Flexo | Medium (plates) | Low | Medium |
| Offset | High (plates) | Medium | Very high |
Why one-off cost is so decisive is detailed in tooling and plate cost.
Where do the cost curves cross?
At low volume digital starts ahead; but as quantity rises, digital's high per-unit cost makes it expensive and flexo takes over. A typical crossover example:
The figures are indicative, but the logic is clear: as quantity rises, flexo/offset overtake digital.
Which one when?
Low volume, many variants, fast turnaround, frequent design changes. With no plate cost, it's economical on small runs.
High volume, fixed design. Flexo on corrugated board, offset on coated carton and high-quality work. One-off cost spreads across units.
In flexo and offset, each colour means a separate plate. Going from 1 to 4 colours roughly quadruples the one-off cost. A low-colour design delivers serious savings at high volume.
Method selection is ultimately a cost optimisation: pin down quantity and colours, then compare total cost across the three methods. For the big picture, return to the packaging pricing guide.
Compare print methods by price
Enter quantity and colours; let PackPrice compare cost by method.
Try FreeFrequently Asked Questions
Which printing method is economical at low volume?
What is the cost difference between flexo and offset?
What determines the choice of printing method?
Price your packaging in seconds
PackPrice calculates every cost line in this guide automatically with AI. Try it free.
Try Free