Guide
Digital vs Flexo Printing
Digital printing has no plates, so it carries no setup charge and makes short runs and multi-SKU ranges genuinely affordable — which is why our minimum is 100 units per design. Flexographic printing needs a plate or cylinder per colour, and that fixed cost only makes sense at high volume, typically tens of thousands of units per design. Below that, digital is cheaper, faster and more flexible.
What is the difference between digital and flexo?
Flexography transfers ink from a raised plate onto the film, one plate per colour. Making those plates costs money and takes time, and they only fit one design. Once running, flexo is extremely fast and the per-metre cost is very low.
Digital printing puts ink directly onto the film from a print head, driven by the file. There is no plate, so there is nothing to pay for before the first pouch and nothing to remake when the design changes.
| Factor | Digital | Flexographic |
|---|---|---|
| Setup cost | None — no plates or cylinders | Plate or cylinder charge per colour, per design |
| Viable minimum | 100 units per design | Typically tens of thousands per design |
| Cost per unit at low volume | Low | Very high once setup is spread |
| Cost per unit at high volume | Higher | Lowest |
| Colour count | Full CMYK at no extra cost | Priced per colour |
| Design changes | Free — resend the file | New plates required |
| Multiple SKUs in one run | Straightforward | Each design is a separate setup |
| Typical turnaround | 2–4 weeks from artwork approval | Longer, plate-making included |
| Special inks and metallics | Limited range | Wide range, including spot metallics |
Why digital suits most brands starting out
The decisive factor is not print quality — modern digital output is retail-grade — it is the shape of the cost. Ten flavours at 100 each is ten plate sets on flexo and one file per design on digital. That difference is what makes a ten-SKU launch possible on a small budget.
It also removes the penalty for changing your mind. Reformulated recipe, new nutritional panel, seasonal edition, a wholesaler who wants their own variant — on digital these are file changes, not tooling changes.
And because colour count does not affect price, you can design without rationing colours. See design your own pouch for how to build artwork that prints cleanly.
When flexo is the right call
Once a SKU is stable and you are ordering in the tens of thousands per design, flexo's per-unit cost wins clearly, and the plate charge amortises to almost nothing. It also gives access to spot colours and specialist metallic inks that digital cannot match exactly.
The usual path is not to choose once. Brands launch and iterate on digital, and move a proven high-volume line to flexo when the numbers cross over. Getting to that crossover with artwork that has already been proved in market is a much safer way to spend a plate budget.
Does digital print match brand colours?
Digital reproduces brand colours through a CMYK build, and for the large majority of palettes the match is close enough that no one notices on shelf. Where it gets harder is very saturated oranges and greens, and specific corporate spot colours that sit outside the CMYK gamut.
If exact colour matters, say so in your enquiry and supply the reference. We check it at proof stage so you see the real result before the run prints, rather than discovering it on delivery. Build artwork in CMYK from the start — see the artwork setup guide.
Not sure which pouch size you need? Tell us what you are packing and we will check the specification.
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Quick answers
Is digital printing as good as flexo for pouches?
For image quality on a retail pouch, yes — digital output is retail-grade. Flexo's advantages are per-unit cost at very high volume and access to specialist spot and metallic inks.
Which printing method do you use?
Digital. It is what allows a 100-unit minimum per design with no plate or setup charges and a 2–4 week turnaround from artwork approval.
Does printing more colours cost more on digital?
No. Digital prints full CMYK as standard, so a photographic full-bleed design costs the same as a two-colour logo at the same size.
At what quantity does flexo become cheaper?
It varies with the number of colours and designs, but the crossover is generally in the tens of thousands per design. Below that, plate costs outweigh the lower running rate.
Can I switch from digital to flexo later?
Yes, and it is a common path. Prove the design and the volume on digital first, then move a stable high-volume SKU across once the plate cost is justified.
Still have questions? Email hello@thepouchworks.com and we'll get back to you within one business day.