Choosing the right printing method is an important part of any custom packaging project. Two common options for flexible packaging are digital printing and gravure printing.

Both can produce high-quality custom printed packaging, but they are suited to different order quantities, budgets, designs, and production requirements.

If you are sourcing stand-up pouches, spout pouches, flat bottom bags, roll stock film, or other flexible packaging, understanding the differences can help you choose a more suitable printing method for your project.

What Is Digital Printing for Packaging?

Digital printing transfers the packaging design directly from a digital file to the printing equipment without requiring traditional printing cylinders or plates.

This makes digital printing particularly useful for projects that require smaller quantities, multiple designs, or frequent artwork changes.

Common applications include:

• New product launches
• Small and growing brands
• Short-run custom packaging
• Multiple SKUs or flavors
• Seasonal and limited-edition packaging
• Market testing

What Is Gravure Printing?

Gravure printing uses engraved cylinders to transfer ink onto the packaging film. Each printing color typically requires its own cylinder.

Because cylinders need to be produced before printing begins, gravure printing involves more preparation than digital printing. However, once production volume becomes larger, it can provide excellent print consistency and competitive unit costs.

Gravure printing is widely used for high-volume flexible packaging production.

Digital Printing vs. Gravure Printing: Key Differences

Factor	Digital Printing	Gravure Printing
Best For	Small to medium runs	Medium to large runs
Printing Cylinders	Not required	Required
Setup Cost	Generally lower	Higher initial setup cost
Multiple SKUs	Very flexible	Less flexible
Artwork Changes	Easier	May require new cylinders
Large-Volume Unit Cost	May be higher	Usually more competitive at scale
Print Quality	High	High and consistent

The best choice depends on the specific project rather than one printing method being universally better than the other.

1. Consider Your Order Quantity

Order quantity is one of the most important factors when choosing between digital and gravure printing.

For smaller packaging orders, digital printing can be attractive because there is no need to produce printing cylinders. This reduces setup requirements and makes short production runs more practical.

For larger recurring orders, gravure printing can become more cost-effective because the initial cylinder cost is spread across a greater number of packages.

2. Consider How Many SKUs You Have

If your brand sells several flavors, scents, sizes, or product variations, digital printing may provide greater flexibility.

For example, a snack brand may need different packaging artwork for five flavors. A personal care brand may have several shampoo or body care formulas using similar pouch sizes but different graphics.

Digital printing can make managing multiple designs easier, particularly when the quantity required for each SKU is relatively small.

3. Compare Setup Cost and Unit Cost

Packaging buyers should consider both initial setup cost and unit cost.

Digital printing generally has lower upfront setup requirements because printing cylinders are not needed. However, this does not necessarily mean digital printing is always the cheapest option.

As order quantities increase, gravure printing can offer a lower unit cost despite the initial cylinder investment.

Instead of comparing printing methods based only on the initial quotation, consider your expected order volume and whether the packaging will be reordered regularly.

4. Think About Future Artwork Changes

Packaging designs change frequently. Brands may update ingredients, product claims, regulatory information, logos, colors, or marketing messages.

With digital printing, changing artwork is generally straightforward because production is based on digital files.

With gravure printing, significant artwork changes may require new printing cylinders, which can add additional cost and preparation time.

If you are still testing your packaging design or expect frequent changes, digital printing may provide greater flexibility.

5. Consider Print Quality and Brand Appearance

Both digital and gravure printing can produce professional, high-quality packaging when the artwork, materials, equipment, and production process are properly managed.

Gravure printing is particularly well established for long production runs requiring consistent colors and detailed graphics.

Digital printing can also reproduce detailed designs and is especially useful for brands that want high-quality graphics in smaller quantities.

The final appearance also depends on other factors, including packaging film, surface finish, artwork quality, color management, and pouch construction.

Which Printing Method Is Better for Startups?

For startups and brands launching a new product, digital printing is often worth considering.

A new brand may not know exactly how quickly a product will sell. Ordering a very large quantity of printed packaging can create unnecessary inventory if the artwork, formula, package size, or branding changes later.

Short-run digital printing can allow brands to start with a more manageable quantity, test the market, and adjust the packaging before moving to larger production volumes.

When Should You Consider Gravure Printing?

Gravure printing may be a better option when:

• Your order quantity is relatively large
• You expect regular repeat orders
• Your packaging design is already established
• You require consistent production across large volumes
• Reducing unit cost at scale is a priority

For established products with stable demand, the initial investment in printing cylinders can make sense over multiple production runs.

Can You Switch from Digital to Gravure Printing Later?

Yes. A brand can begin with digital printing for smaller orders and later move to gravure printing as sales and packaging quantities increase.

This can be a practical strategy for new products. Digital printing provides flexibility during the early stage, while gravure printing may offer better economics once order volumes become sufficiently large.

When switching printing methods, color and artwork should be reviewed carefully because different printing processes may produce slight differences in the final appearance.

How to Choose the Right Printing Method

Before requesting a custom packaging quotation, prepare the following information:

• Packaging type
• Bag or pouch dimensions
• Required material structure
• Number of artwork designs or SKUs
• Quantity required per design
• Printing colors and artwork files
• Surface finish requirements
• Expected future order volume

Providing this information allows your packaging supplier to evaluate whether digital printing or gravure printing is more appropriate for your project.

Custom Printed Packaging from UNALILIA

UNALILIA provides custom flexible packaging and printing solutions for food, pet food, personal care, household cleaning, supplements, and other products.

Custom packaging options include:

• Stand-up pouches
• Flat bottom bags
• Spout pouches
• Side gusset bags
• Roll stock film
• Custom printed flexible packaging
• Labels and stickers

Based on your packaging type, artwork, number of SKUs, order quantity, and budget, we can discuss suitable printing options for your project.

Request a Custom Packaging Quote

Not sure whether digital printing or gravure printing is right for your packaging?

Send UNALILIA your packaging type, dimensions, artwork, number of designs, material requirements, and estimated quantity. We can review your requirements and discuss an appropriate packaging and printing solution.

Contact UNALILIA today to discuss your custom printed packaging project and request a quote.

Frequently Asked Questions

Is digital printing good for custom packaging?

Yes. Digital printing is particularly suitable for short-run custom packaging, multiple SKUs, product launches, seasonal designs, and brands that need greater flexibility with packaging artwork.

Is gravure printing better for large packaging orders?

Gravure printing is commonly used for larger production runs. Although printing cylinders require an initial investment, the unit cost can become more competitive as production volume increases.

Which printing method has a lower MOQ?

Digital printing generally supports smaller production quantities because it does not require traditional printing cylinders. Actual minimum order quantities depend on the packaging type, dimensions, materials, and production requirements.

Which has better print quality: digital or gravure printing?

Both methods can produce high-quality custom packaging. Gravure printing is well suited to consistent high-volume production, while modern digital printing can provide detailed, professional graphics for shorter runs.

What information do I need for a custom packaging quote?

Provide your packaging type, size, material requirements, artwork or number of designs, required quantity, product application, and any special features such as zippers, spouts, windows, valves, or surface finishes.