What is the difference between flexo and digital printing?

When choosing between these two technologies, the biggest factors boil down to material compatibility, cost-efficiency for volume, and quality consistency—all areas where the Flexo Printing Machine excels for most packaging or large-format needs.

1. Material Compatibility: Flexo Printing Machine Handles More Surfaces

Digital printing is limited to smooth, non-porous materials (like standard paper or thin plastic films) because its ink relies on direct deposition. In contrast, the Flexo Printing Machine uses flexible plates and adaptive ink systems, making it far more versatile:
The Flexo Printing Machine works with rough surfaces (corrugated cardboard for shipping boxes) and non-traditional materials ( metal foils for food packaging or thick vinyl for banners).
Digital printing often struggles with thick or textured substrates, as ink can smudge or fail to adhere evenly.

2. Cost & Efficiency: Flexo Printing Machine Shines for Bulk Orders

For businesses that need large production runs (a common scenario for packaging or promotional materials), the Flexo Printing Machine delivers better long-term value:
While digital printing has lower setup costs (no need for plates), its per-unit cost stays high—making it only cost-effective for small batches (100–500 pieces).
The Flexo Printing Machine requires initial plate setup, but once running, its per-unit cost drops significantly. For orders over a few thousand pieces, it cuts total costs by a notable margin and runs much faster (digital printers typically handle 50–100 sheets per minute, while a mid-range Flexo Printing Machine hits speeds that are several times higher).
 

3. Quality Consistency: Flexo Printing Machine Delivers Stable Results for Large Runs

Both technologies produce sharp prints, but the Flexo Printing Machine maintains consistency better for long productions—critical for brands needing uniform packaging:
Digital printing can have slight color variations between batches (due to ink cartridge changes or machine calibration shifts), which is risky for brands with strict color standards.
The Flexo Printing Machine uses fixed plates and automated ink control, so every piece in a 10,000-unit run matches the original design. It also handles bold colors and large solid areas (brand logos on packaging) more smoothly than digital, with no "banding" (visible ink lines).

Conclusion

While digital printing works for small, custom jobs, the Flexo Printing Machine is the clear choice for businesses focused on bulk production, versatile material use, and consistent quality. Its ability to handle diverse substrates, lower per-unit costs for large runs, and stable print results make it a reliable investment for scaling your printing needs.
If you’re ready to find a Flexo Printing Machine that fits your specific product , reach out to FANGBANG GROUP today—we’ll help you compare models and get a solution tailored to your order volume. And if you want to explore more industry tips for printing and operations, feel free to visit the Bilibili Homepage for additional insights!