Digital Inkjet Printing- a Game Changer for Packaging Industry

The packaging industry is evolving. Digital print technology, especially inkjet printing, is leading the change. With rising consumer demands and…

Yu Dai
January 2, 2025
Digital Inkjet Printing

The packaging industry is evolving. Digital print technology, especially inkjet printing, is leading the change.

With rising consumer demands and a focus on sustainability, packaging companies need to innovate. Inkjet printing offers a solution, reshaping how packaging is produced.

This article explores how inkjet technology is transforming packaging, its benefits, and the challenges ahead.


What Is Digital Inkjet Printing?

Inkjet printing is a digital printing method that applies liquid ink directly onto surfaces using tiny nozzles.

It offers high precision and flexibility, making it perfect for customized designs and short production runs.

This technology is widely used in packaging, where speed and adaptability are expected.

The Inkjet Printing Process

Inkjet printing uses the CMYK color model—Cyan, dMagenta, Yellow, and Black—to produce a wide range of colors on packaging.

Step 1: Digital File Preparation
A design is created digitally and converted into CMYK values, specifying how much of each color is needed.

Close Up Rear Large Inkjet Printer Working On Viny
Inkjet printer is working

Step 2: Ink Selection and Print Head
Each CMYK ink is stored in separate cartridges. The print head sprays tiny droplets of ink onto the substrate (packaging material) through microscopic nozzles.

Hand Using Tablet Control With Inkjet Printer Prin
Inkjet Printer Testing

Step 3: Layering the Colors
The print head applies the inks in layers, blending them to create the desired color. For example, Cyan and Magenta mix to form purple.

Step 4: Ink Absorption and Drying
The substrate absorbs the ink. UV inks are cured by UV light for durability, while water-based inks dry naturally.

Step 5: Final Printing
The process results in high-quality, full-color packaging. The CMYK system ensures accurate, consistent color reproduction.


The Benefits of Digital Inkjet Printing Packaging

Inkjet printing is becoming more popular in packaging. The global market for inkjet printing in packaging is projected to reach $12.6 billion by 2023.

This digital printing method in packaging provides cost savings, customization, speed, and sustainability. It’s becoming the preferred choice for businesses looking for efficient and environmentally friendly packaging solutions.

Cost-Effectiveness

Inkjet printing offers significant cost savings, especially compared to traditional methods. It eliminates setup costs, such as plates, which can be expensive.

According to Smithers, inkjet reduces setup costs by up to 30%, making it ideal for smaller businesses (Smithers, 2021).

Customization and Flexibility

Inkjet enables easy customization, allowing for personalized designs or unique packaging. A study by Packaging Strategies found that 61% of consumers are more likely to purchase products with personalized packaging (Packaging Strategies, 2020).

Inkjet allows brands to quickly change designs without extra setup fees, providing flexibility in fast-moving markets.

Examples of Digital Printing Packaging

Share A Coke With Even More

Brands like Coca-Cola and Nutella are using inkjet printing to personalize packaging.

Coca-Cola’s “Share a Coke” campaign boosted sales by 2.5%, while Nutella’s inkjet-printed jars led to a 7% sales increase.

Speed and Efficiency

Inkjet printing speeds up production. Modern printers can produce up to 1,000 linear feet per minute, compared to slower traditional methods.

Single-pass printing can reduce turnaround times by 40% or more, helping businesses meet tight deadlines (Smithers, 2021).

Environmental Benefits

Inkjet uses water-based inks, reducing VOC emissions by up to 50% compared to solvent-based inks (EPA, 2020). It also consumes up to 40% less energy than traditional printing, lowering businesses’ carbon footprints (Smithers, 2021).


Inkjet Printing in Packaging Industries

Inkjet printing is being used in a wide range of packaging applications.

  • Food and beverage: Inkjet prints expiration dates and batch codes directly on packaging, reducing costs.
  • Cosmetics: Inkjet printing enables limited edition packaging and personalized designs.
  • Pharmaceuticals: Inkjet technology ensures compliance by printing variable data on clinical trial medications.
  • Corrugated packaging: Companies like DS Smith use inkjet for customized retail-ready packaging, improving brand visibility.

The flexibility of digital inkjet makes it ideal for various packaging sectors, offering quick, high-quality prints that meet market demands.

Advances in Inkjet Printing Technology

Inkjet technology has made significant advancements in recent years. Modern printers offer high resolutions and fast speeds, allowing for high-quality prints and efficient production.

Some of the latest innovations include:

  • Single-pass printing: Faster production with no loss of quality.
  • UV-curable inks: More durable and faster drying.
  • Water-based inks: More eco-friendly options.
  • Advanced printheads: Greater precision and reliability.

These advancements make inkjet printing a strong option for both flexible packaging and corrugated packaging applications. They challenge the dominance of traditional analog printing methods.


Inkjet Printing Challenges

While inkjet printing offers many advantages, there are challenges in its widespread adoption.

Material compatibility remains a major hurdle. Not all substrates work well with inkjet inks, limiting its use in certain packaging applications.

Environmental concerns also persist, particularly regarding the recyclability of inkjet-printed packaging. However, these challenges also present opportunities for growth:

  • Developing biodegradable inks.
  • Combining inkjet with smart packaging solutions.
  • Expanding into flexible packaging.
  • Speeding up inkjet printing for long-run production.

By addressing these issues, the packaging industry can unlock the full potential of inkjet technology.


Custom Inkjet Digital Printing packaging

Here’s a simple guide to integrating inkjet printing into your packaging process:

  1. Assess your needs: Understand your current and future packaging goals.
  2. Research technologies: Explore available digital inkjet printing options.
  3. Cost-benefit analysis: Compare inkjet’s ROI to traditional printing methods.
  4. Choose equipment: Select printers that match your production and quality needs.
  5. Train staff: Focus on both technical skills and design considerations.
  6. Start small: Begin with pilot projects to test the process.
  7. Scale up: Expand based on successful tests.
  8. Optimize: Regularly review and refine your processes.

When integrating inkjet printing, consider the type of press and the compatibility with your chosen substrate. A thoughtful approach ensures smooth adoption.


Embracing the Digital Inkjet Revolution

Inkjet printing is more than just a trend. It’s revolutionizing the packaging industry.

With its ability to offer personalization, efficiency, and sustainability, inkjet printing meets the evolving needs of businesses and consumers.

As technology improves, the potential for creativity and innovation grows.

Are you ready to embrace the future of packaging with inkjet printing?

Inkjet Printing vs. Offset Printing

Inkjet printing uses digital technology to spray liquid ink directly onto a surface, providing precision and flexibility. It’s perfect for smaller runs and custom designs, allowing quick changes and personalization.

On the other hand, offset printing transfers ink from a metal plate to a rubber blanket before it reaches the substrate. This method is ideal for high-volume jobs and produces consistent, sharp results, especially for paper-based materials.

While inkjet is great for flexibility and cost-effectiveness in short runs, offset printing is better suited for large-scale production with crisp, detailed outputs.

If you’re curious about how these methods compare in different contexts, check out our detailed article on the subject.

Wrappint it Up

In this article, we’ve highlighted the benefits of digital inkjet printing in the packaging industry—its flexibility, cost-effectiveness, and ability to create high-quality, customized designs.

Inkjet printing not only helps reduce waste but also accelerates production, making it an ideal solution for businesses focused on innovation and sustainability.

At WITPAX, we take care of the technical details for packaging, allowing you to focus on your product.

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Explore our “Packaging 101” series for expert insights and practical tips on enhancing your packaging strategy.