The Cost of Digital Printing for Corrugated Packaging: Q&A with Matthew Condon, Domino Printing Sciences
As brands and packaging converters navigate changing markets and consumer demands, the search for flexible, cost-effective corrugated packaging solutions is intensifying. Digital printing has emerged as a promising solution, offering benefits such as increased flexibility, reduced waste, and streamlined operations compared to traditional methods. To better understand its value and cost implications, Frazer Chesterman spoke with Matthew Condon, Business Development Manager for Corrugated at Domino Printing Sciences.
Frazer Chesterman: Matthew, digital printing is gaining traction in corrugated packaging – why is that?
Matthew Condon: Brands are increasingly demanding seasonal or limited-edition packaging on a just-in-time basis to enhance consumer appeal and reduce overstock waste. To respond to their demands effectively, converters need more agile printing solutions that will allow them to respond faster, with only minimal waste when producing those shorter runs. Digital printing technology is a great fit for these applications, reducing costs by eliminating traditional plates and drastically cutting down on setup time.
Frazer: Isn’t digital printing more costly compared to traditional methods?
Matthew: Digital printing operational costs are best achieved when short and medium runs are considered. Digital can significantly reduce ongoing operational expenses by removing plate-making, minimising waste from overproduction, and enabling rapid design changes without extra costs. Utilising digital correctly can deliver substantial savings and efficiency gains.
Frazer: When would you recommend digital printing over traditional methods?
Matthew: While traditional methods remain cost-effective for large volumes, digital’s strengths lie in agility and reducing waste, critical for meeting fast-changing market demands. Digital printing excels at producing cost-efficient short-to-medium print runs, seasonal campaigns, and personalised packaging.
Frazer: What other strategic advantages does digital printing offer?
Matthew: Besides cost efficiency, digital printing can enhance brand visibility through the creation of multiple, vibrant, high-quality graphics, enabling brands to differentiate products on crowded shelves. The ability to produce variable or customised premium packaging designs at a fast turnaround also enables converters to better support their brand customers in delivering an unboxing experience that will nurture consumer engagement. Digital printing presses do not require specialist operators, alleviating labour challenges and operational complexity.
Frazer: How can businesses justify the upfront costs associated with digital printing?
Matthew: The initial investment is offset by reduced operational costs – no plates, less waste, minimal downtime – with quicker turnarounds for improved market adaptability. By investing in digital, companies can gain a significant competitive advantage through enhanced responsiveness and innovation in packaging design.
Exploring the Benefits of Digital Printing for Corrugated Packaging
Digital printing is emerging as a highly flexible and cost-effective solution for corrugated packaging, particularly suited to today’s fast-paced markets. Unlike traditional methods, digital eliminates plate-making, significantly reducing setup time, waste, and associated costs. While initial investments in digital presses and inks may appear to be higher, operational savings in the long term can deliver substantial value for converters. Ideal for short-to-medium runs and personalised campaigns, digital printing offers strategic benefits including the ability to differentiate from traditional converters, overcome challenges in finding skilled labour, and improve market responsiveness. Find out more about Domino’s X630i digital corrugated printing press here.