FAQ
What's the difference between flexo and digital printing?
When to use flexographic printing, when to use digital, and why most CPG brands need both.
It's the most-asked question on our quote calls. The short answer: flexo is for predictable repeat work, digital is for short runs and rapid iteration. Most growing CPG programs use both.
Flexographic printing
Flexo uses physical printing plates — one per color — mounted on cylinders. Setup costs are real (plates, anilox rolls, ink mixing) but per-label cost drops sharply at higher volumes. Best for:
- Long runs (10,000+ labels)
- SKUs that don't change frequently
- Multi-color jobs with embellishments
- Specialty substrates and finishes
Digital printing
Digital uses inkjet or toner — no plates required. Setup is essentially zero, so short runs are economic. Variable data (each label different) is built in. Best for:
- Short runs (under 5,000 labels)
- Rapid iteration and frequent revisions
- Multiple SKUs in one job
- Variable data, sequential numbers, or QR codes
The crossover zone
Between 5,000 and 10,000 labels, both technologies can be cost-competitive depending on substrate and embellishments. Your label vendor should be able to quote either and recommend the better fit.
Why most CPG brands need both
A typical multi-SKU brand has high-volume hero SKUs (flexo) and long-tail SKUs that don't justify flexo setup costs (digital). Running both lines under one vendor — with one quality program, one account team, and one source of accountability — is operationally simpler than splitting work across two vendors.