Short answer: digital printing is usually worth reviewing when you have several SKUs, changing artwork, a launch or trial quantity, or a high risk of obsolete packaging. Conventional printing often becomes more practical when the design is stable and the repeat volume is large enough to spread setup costs.
Compare the project, not only the price per kilogram
| Project condition | Digital is worth reviewing | Conventional may fit better |
|---|---|---|
| SKU mix | Many designs with smaller quantities per SKU | One or a few stable designs |
| Artwork changes | Frequent revisions, localisation or test launches | Approved artwork repeated for a long period |
| Inventory risk | Demand is uncertain or packaging may become obsolete | Forecast and repeat demand are stable |
| Colour and effects | Standard process-colour work within the chosen route | Special inks, coatings or effects that need a different process |
| Volume | Pilot, launch or segmented volume | Long, repeat production runs |
Digital printing does not remove the packaging-engineering work
The printed web still needs the right substrate, laminate, sealant, thickness, friction, repeat, eye mark, width, core, roll diameter and winding direction. A good print route with the wrong roll specification can still stop a VFFS, HFFS or flow-wrap line.
Calculate total project cost
Compare setup, printing, lamination or coating, slitting, samples, freight, storage, write-offs and the cost of a late artwork change. A lower unit price can be the more expensive choice if it creates excess stock across several SKUs. Digital can also be the wrong choice if the structure, finish or volume sits outside the practical route available for that project.
Ask these questions before requesting a quote
- How many SKUs and how much of each one?
- Is the artwork final, or likely to change?
- What complete structure and sealant does the product need?
- What are the web width, repeat, core, maximum diameter and unwind?
- Will the first order be a market test, a machine trial or normal production?
- Which colour reference, finish and inspection method will be used?
- What repeat demand is realistic over the next 6–12 months?
Use a proof for appearance and a trial for runnability
A print proof answers artwork, colour and layout questions. It does not replace a machine trial when the structure, dimensions or line conditions are new. Agree what each sample proves before using it to approve bulk production.
Choose the next page by supplied format
For printed webs used on automated lines, start with the Specialty Rollstock Hub. For single-serve sachets, review Custom Sachet Rollstock. If matt or gloss appearance affects handling or seal areas, use the Matt and Gloss Finishes page.
Send a print-route brief
Share the product, complete structure or current sample, SKU count, quantity per SKU, artwork status, finish, machine and roll specifications through the Specialty RFQ. XLD will compare the feasible print and supply routes without assuming that one method is always better.
Last reviewed: 13 October 2026.
