Cardboard boxes are an essential part of modern packaging, providing durability, versatility, and eco-friendliness. However, businesses often overlook the fact these boxes also serve as a canvas for branding, product information, and marketing. So, how are cardboard boxes printed?
Understanding Cardboard Boxes
Cardboard boxes are made from corrugated fiberboard, which consists of a fluted corrugated sheet sandwiched between two flat linerboards. This structure gives the boxes their strength and rigidity, making them ideal for shipping and storage. The printing process must account for the texture and composition of corrugated materials to achieve high-quality results.
Printing Techniques for Corrugated Boxes
1. Flexographic Printing
Flexographic printing, or flexo, is the most common method for printing on corrugated boxes. It uses flexible relief plates made of rubber or photopolymer to transfer ink onto the substrate. Here’s how it works:
– Plate Preparation: Plates are prepared with the desired image or text raised on the surface.
– Inking: The plates are coated with fast-drying, water-based inks.
– Impression: The inked plates press against the corrugated board, transferring the image.
Advantages:
– High-speed printing suitable for large volumes.
– Versatile, capable of printing on various substrates.
– Economical for long runs.
2. Digital Printing
Digital printing is gaining popularity for its flexibility and precision. It works similarly to an inkjet printer but on a much larger scale. Here’s the process:
– File Preparation: Digital files of the design are prepared and adjusted for the printing process.
– Printing: The digital printer applies ink directly to the corrugated board without the need for plates.
Advantages:
– No need for printing plates, reducing setup costs.
– Ideal for short runs and custom printing.
– Quick turnaround times with high-quality results.
3. Lithographic Lamination
Lithographic lamination, or litho-lam, combines the high-quality graphics of offset printing with the durability of corrugated boxes. Here’s how it works:
– Offset Printing: Designs are printed on high-quality paper using traditional offset printing methods.
– Lamination: The printed sheets are then laminated onto the corrugated board.
Advantages:
– Superior print quality with vibrant colours and sharp images.
– Ideal for high-end packaging and retail displays.
– Capable of printing intricate details and photographic images.
4. Screen Printing
Screen printing involves transferring ink through a mesh screen onto the corrugated board. This method is less common for large-scale corrugated box printing but is used for specific applications:
– Screen Preparation: A stencil of the design is created on the screen.
– Inking: Ink is pushed through the screen onto the substrate.
Advantages:
– Suitable for large, bold designs.
– Can be used for specialty inks and finishes.
– Economical for short runs and unique designs.
Sustainable Printing Practices
As sustainability becomes increasingly important, printing processes are adapting:
– Eco-Friendly Inks: Water-based and soy-based inks are replacing traditional solvent-based inks.
– Recyclable Materials: Innovations in substrates and coatings ensure that printed corrugated boxes remain fully recyclable.
Conclusion
That is our answer to “how are cardboard boxes printed?” The process of printing cardboard boxes combines creativity and technology to create vibrant and functional packaging. From selecting the right materials to choosing the best printing method, each step is crucial to ensure the final product is both eye-catching and durable. Understanding this process helps appreciate the effort and innovation behind the everyday cardboard box.
