Are you torn about which printing method to choose when customizing your bags? Supplier recommendation when you do not understand why so recommended, can not figure out the difference between the two? The advantages and disadvantages of both?
This guide breaks down their costs, quality, sustainability, and ideal use cases to help you make an informed decision.
1. Gravure Printing: Suitable for High-Volume Orders
Gravure printing is a direct printing method. Its core principle is to use the depressions on the image and text on the gravure plate to store ink, and transfer the ink to the substrate through the pressure of the printing press to form clear patterns and text.
Best For:
Long runs (20,000+ units)
Complex designs (fine details, gradients)
Brands needing Pantone color accuracy
Pros:
Superior print quality (up to 150 LPI resolution)
Low per-unit cost for bulk orders
Wide material compatibility (including metallized films)
Cons:
High upfront costs (cylinders cost $3,000+ per color)
Long setup time (weeks for cylinder engraving)
Less eco-friendly (solvent-based inks require VOC management)
Real-World Example:
A global snack brand uses gravure printing for 10 million+ pouches/year due to consistent quality and economies of scale.
2. Digital Printing: Agile & Sustainable for Short Runs
Digital printing is a production method using digital technology for printing, which can realize fast and flexible printing services by directly controlling the printing machine through digital files without the need of plate making.
Best For:
Small batches (1,000–50,000 units)
Fast prototyping & market testing
Personalized/customized packaging
Pros:
No plate costs – ideal for startups and limited editions
Faster turnaround (samples in 48 hours vs. weeks)
More sustainable (water-based/UV inks, less waste)
Cons:
Higher per-unit cost for large orders
Limited material options (some films require pre-treatment)
Slightly lower opacity vs. gravure (but gap is narrowing)
Real-World Example:
A luxury skincare brand uses digital printing for seasonal gift sets, allowing last-minute design tweaks.
3. Key Decision Factors: Which Should You Choose?
| Dimensions | Gravure Printing | Digital Printing |
| Applicable scenarios | Large batches (20,000+), long-run orders | Small batches, fast proofing, personalized customization |
| Cost structure | Plate-making fee ($3000+), but low unit price | No plate-making fee, higher unit price (suitable for short orders) |
| Printing quality | High precision (150 LPI+), strong spot color reproduction | Close to gravure in recent years (such as HP Indigo 20000′s 90% Pantone coverage) |
| Delivery time | Long (One week for plate making) | Short (7-15 days production time) |
| Environmental protection | Solvent-based inks need to deal with VOC | Water-based/UV inks, low carbon footprint |
| Case | Coca-Cola brand continuous pattern printing | Limited edition packaging for niche cosmetics |
Still unsure?
Annual demand > 100,000 → Gravure
Require variable data/urgent order → Digital
Limited budget but high quality required → Hybrid solution (gravure base color + digital pattern)
Industry trend: Growth of digital printing in anti-counterfeiting labels (such as serial number printing) and seasonal packaging (according to Smithers’ forecast, digital packaging printing will account for 21% share in 2026).
4. Future Trends: Hybrid Solutions Are Rising
Many brands now combine both methods:
Gravure for base colors (cost-effective at scale)
Digital for variable data (expiry dates, promotions)
According to Smithers 2024, the digital packaging print market will grow by 12.3% annually, driven by demand for:
Short runs (limited editions, regional campaigns)
Smart packaging (interactive labels)
Eco-friendly inks (brands like Nestlé aim for 100% recyclable packaging)
5. Conclusion: Match Your Needs to the Right Tech
Gravure = Cost efficiency + premium quality for mass production.
Digital = Speed + flexibility for small batches and personalization.
Need a recommendation?
➡ “Contact our packaging experts for a free print sample based on your artwork!”