Corrugated Box Printing: Flexo, Digital and Litho-Laminate Explained

Corrugated boxes protect goods in transit and increasingly serve as brand-communication surfaces. The right printing method depends on run length, colour complexity and budget. BestPackFactory produces custom corrugated boxes from our Shenzhen factory.

Flexographic Printing

Flexo is the standard for corrugated. Inks are applied directly to the corrugated surface through rubber printing plates. Typical registration: ±2–3 mm. Suitable for: logos, text, simple patterns in 1–4 colours. Cost per plate: USD 80–150. At 1,000 boxes, this is the most economical option.

Digital Printing

UV-inkjet printing directly onto corrugated. No plates, fast turnaround (3–5 days), excellent for prototypes and short runs (50–500 boxes). Image quality rivals litho. Cost per box is higher than flexo at scale, but the absence of plate costs makes it cheaper for runs under 500 boxes.

Litho-Laminate (Litho Mount)

Full-colour offset-printed art paper is laminated to the corrugated board. Delivers near-retail-packaging print quality on a shipping box. Best for: premium e-commerce, gift boxes shipped in their own container (SIOC), influencer mailers. Cost premium: 30–60% over flexo. MOQ typically 1,000 boxes.

Artwork Specifications

• Flexo: vector art (AI, EPS, PDF); 45–65 lpi halftone; CMYK with spot Pantone acceptable
• Digital: 300 dpi raster or vector; full CMYK + white ink on dark boards
• Litho-laminate: 300 dpi; bleed 5 mm; same as retail offset spec

Flute Selection

E-flute (1.5 mm): retail shelf boxes, gift packaging. B-flute (3 mm): standard shipping box, good stacking strength. C-flute (4 mm): heavy goods shipping. Double-wall BC-flute: fragile or heavy items over 10 kg.

MOQ and Lead Times

Flexo: MOQ 1,000 boxes, 12–18 days. Digital: MOQ 50 boxes, 5–8 days. Litho-laminate: MOQ 1,000 boxes, 15–20 days.