Digital Printing Press
Folding Cartons

What does a digital printing press do for folding cartons?

Digital printing presses print directly onto folding carton stock based on digital print data. Unlike conventional printing processes, no fixed printing plates are required. This allows images, text, codes, or designs to be quickly changed, versioned, or personalized.

For packaging production, this means shorter lead times, less waste, and greater flexibility in the ongoing production process. At the same time, high-quality prints with fine details, gradients, photos, complex graphics, and precise negative text can be produced.

Our solution for digital sheet-fed printing for the folding carton market

The VariJET 106

integrates inkjet technology into the platform of the high-performance Rapida 106 offset press. The consistent modular concept combines the opportunities of digital inkjet with the acknowledged print and inline finishing capabilities of the offset process.

The VariJET 106 delivers offset substitutable quality with an extremely broad color gamut. Highly productive platform for customers from 0.5 million to 2.0 million B1-sheets per month. Modular platform capable of utilizing offset and flexo functionality. Food-safe water-based inks to meet current and future regulatory and environmental standards.

Learn more about the VariJET 106

Learn more about the
VariJET 106

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No printing plates required

Print data can be processed directly. This saves setup time, reduces setup costs, and makes it easier to make last-minute design changes.

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Cost-effective for small and medium print runs

Even smaller quantities can be produced cost-effectively, as there are no high plate or setup costs.

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Fast Production Times

From uploading print data to the finished packaging, the process can be completed significantly faster than with traditional methods.

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Personalization and Versioning

Custom content, QR codes, barcodes, serial numbers, tracking codes, or changing designs can be integrated directly.

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High Print Quality

Fine lines, photos, color gradients, complex graphics, and negative text can be reproduced with precision and high quality.

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Reduced Inventory

Folding cartons can be produced on demand. This reduces inventory levels, capital tied up in inventory, and unnecessary overproduction.

For which applications is digital printing on folding cartons suitable?

Digital printing on folding cartons is particularly well-suited for packaging projects that require flexibility, speed, and a wide variety of options. These include, for example:

Application	Advantages of Digital Printing
Brand Packaging	High-quality prints for a compelling product presentation
E-commerce Packaging	Flexible designs, changing content, and quick post-production
Seasonal Promotions	Short lead times for campaigns, promotions, and special editions
Market Tests	Small print runs without high setup costs
Regional Variations	Different languages, designs, or product information in a single process
Customized Packaging	Integration of variable data, codes, or personalized content
Display Solutions	Precise print quality for eye-catching packaging and point-of-sale designs

Digital printing or conventional printing: When is which process worthwhile?

Digital printing shows its strengths especially when orders need to be produced quickly, flexibly, or with many variations. Conventional processes remain relevant for very high, consistent print runs. However, for many modern packaging requirements, digital printing offers clear advantages.

Printing plates

Digital printing for folding cartons Not required

Conventional printing Required

Setup time

Digital printing for folding cartons Short

Conventional printing Usually higher

Small and medium print runs

Digital printing for folding cartons Very cost-effective

Conventional printing Often less efficient

Design changes

Digital printing for folding cartons Quick to implement

Conventional printing Associated with additional effort

Personalization

Digital printing for folding cartons Very easy to implement

Conventional printing Limited or time-consuming

Variable data

Digital printing for folding cartons Can be integrated directly

Conventional printing Usually an additional process

Inventory management

Digital printing for folding cartons Demand-based production possible

Conventional printing Often larger production quantities

Market tests and promotions

Digital printing for folding cartons Very well suited

Conventional printing Often requires a longer lead time

Quality, Flexibility, and On-Demand Production in Digital Packaging Printing

High Color and Print Quality for Sophisticated Packaging

Digital packaging presses deliver high-quality prints for sophisticated folding cartons:

precise reproduction of photos, color gradients, and fine details
clear presentation of product information and brand elements
consistent quality with high repeatability

Greater Flexibility in Packaging Production

Digital printing makes it easier to quickly adapt to new market and customer requirements:

last-minute changes to layout, text, or imagery
multiple designs or variations in a single print run
ideal for product variations, seasonal campaigns, and regional requirements

On-Demand Production

Through on-demand production, digital printing can reduce resource consumption and warehousing costs:

no printing plates required
less waste, overproduction, and inventory
lower transportation and warehousing costs for changing designs or small print runs

FAQ: Digital Printing Presses for Folding Cartons

Is the color quality in digital printing comparable to that of conventional printing?

Yes, modern digital printing systems achieve very high print quality. Fine details, gradients, photos, complex graphics, and precise negative text can all be reproduced with high quality. For many folding carton applications, the quality is very comparable to that of traditional methods.

Is digital printing more expensive than traditional printing methods?

That depends heavily on the print run, the number of designs, and production requirements. For very small, small, and medium print runs, digital printing is often more cost-effective because it does not require printing plates, setup times are reduced, and there is significantly less waste. Waste, in particular, can be a major cost factor in packaging production. For very large, consistent print runs, conventional methods may still offer advantages.

At what print run size does digital printing become cost-effective?

Digital printing offers its greatest advantages for very small to medium print runs, as well as for frequently changing designs. Since no printing plates are required, many setup costs and long setup times are eliminated. In addition, there is less setup waste, which can be a significant cost factor in traditional printing processes. This makes it possible to produce even smaller orders cost-effectively.

Can custom folding boxes be produced?

Yes. Digital printing presses allow for the integration of variable data—such as serial numbers, QR codes, barcodes, tracking codes, sweepstakes codes, or personalized customer information—directly into the printing process.

Can multiple designs be produced in a single print run?

Yes. Versioning and different designs are a key advantage of digital printing. This makes it possible to efficiently produce different product variants, language versions, promotional packaging, or regional designs.

How quickly can new packaging designs be implemented?

New designs can be produced very quickly, since no printing plates need to be created. Changes to the layout, text, or design can be made directly in the print files and incorporated into production more quickly.

Is digital printing more sustainable than traditional printing methods?

Digital printing can be more sustainable because it produces less waste, does not require printing plates, and allows packaging to be produced on demand. This reduces material consumption, inventory levels, and potentially also transportation costs.

Knowledge Base

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