CHAPTER – 1

INTRODUCTION / PREAMBLE

We at Vaibhav Printpack, a highly regarded company in Bangaluru, Karnataka, that was

founded in 2021, produce and sell a range of Printed Laminated Rolls that have been quality-
approved. Along with these items, we also sell printed BOPP film rolls, printed and plan BOPP
bags, stand-up zipper pouches, Tiranga and Tulsi aluminium foil containers, and many more.
These products are produced in our fully-equipped production facility using raw materials of the
highest quality while adhering to standards set by the industry. We source our raw materials from
the most reputable and trustworthy vendors in the market. These product lines are available
based on client requests.

Infrastructural Facilities: We have divided our infrastructure into different sections to facilitate
hassle-free operations. Our productions facility is equipped with the newest tools and machinery.
The equipment placed in our production unit can handle large orders within the specified time
frame because of the upgraded equipments’s extremely high output rate.

Our Team: Our staff of skilled engineers is dedicated and competent, and they have a proven
track record of producing products. We occasionally hold training and seminars to ensure that
our specialists are up to date on industry trends. Within the agreed-upon time limit, we are
providing quality-approved products at affordable pricing. Customers esteem the offered
collection highly for its anti-corrosion properties, flawless finish, top performance, and extended
functional life.
Packaging printers are an essential asset for businesses looking to elevate their products.
Packaging printers offer versatility, efficiency, and high-quality direct to package printing
solutions. Commercial/Industrial packaging printers are designed to cater to various materials
and shapes, including boxes, bags, labels, and more, ensuring that your products stand out on the
shelves. They are equipped with the latest printing technology, offering vivid colors and sharp
details, which are crucial for capturing customer attention and conveying brand messages
effectively. Ease of use is another hallmark of our printers. With user-friendly interface and
software, they integrate seamlessly into your production line, reducing setup time and increasing
productivity.
Packaging printing means any lithographic, flexographic, gravure, or letterpress printing that
results in identifying or beautifying paper, paperboard or cardboard products to be used as
containers, enclosures, wrappings, or boxes.

Types of packaging printing methods

In a packaging design process, you’ll need to compare and contrast the various printing methods
suitable to your product. There are several packaging printing techniques available, and each of
them fits different end-use applications.

1. Flexography
For several decades, flexographic printing, commonly referred to as “flexo” has stood as
the preferred method for high-volume product labels and flexible packaging production,
particularly in the food and beverage industry. Renowned for its adaptability, flexo
employs a flexible relief plate made of rubber wrapped around a cylinder for seamless
and efficient printing.

In the flexography process, an anilox roller, a cylinder with microscopic “cells” made of
metal or ceramic, transfers ink to the relief plate. As the plate contacts the substrate, the
image is transferred at high speeds and low operating costs. Continuous advancements in
 flexography have introduced greater automation and improved quality that can now rival
traditional offset printing.
Flexography emerges as a cost-effective solution for extensive print runs with fewer
printing constraints. Its versatility shines, allowing the printing of almost any shape or
format-unlike lithography, which necessitates a flat substrate. Ideal for high-speed
manufacturing lines, where labels adhere to roll-formed products instead of sheets,
flexography excels in achieving high-quality print images and offers the potential for
perfectly matched spot colors.
While flexography proves optimal for companies seeking cost-effective solutions, it does
present challenges. Serialization and unique codes can be cost-prohibitive in traditional
flexographic printing, especially for low-volume jobs with numerous SKU or design
variations. Lower-cost flexographic print providers may struggle to achieve the crisp
print quality needed for intricate designs, smooth color gradients, and accurate
representations. As companies weigh the benefits, the limitations of flexography must be
carefully considered based on the specific requirements of the packaging project at hand.

2. Lithography
Lithography, also known as offset printing, finds widespread application for large or flat
items such as custom folding cartons, corrugated packaging, and retail displays. In the
litho printing process, the image is meticulously set onto an aluminum plate and
subsequently transferred to a rubber blanket for processing. The final step involves the
image being printed in to a substrate, with the option for additional finishes such as
coatings or varnishes to enhance appearance and provide protective layers.

Lithography stands out for its versatility in printing small to large format sizes, making it
well-suited for high-volume production with intricate graphics. Often hailed as the
quality standard in package printing, offset litho sets a benchmark against which other
processes are measured. Notably, color-matching achieves exceptional accuracy, and the
option for post-print finishes, such as gloss coating or foil embellishment, adds a touch of
luxury and quality. In addition to the superior quality and diverse finishing options, offset
litho boasts fast printing speeds, contributing to efficient production.
 Lithography’s custom-made aluminum plates contribute to relatively higher costs,
particularly in shorter print runs. Regardless of volume, most print providers impose
setup fees for plate production. This plate cost, coupled with the inherent customization
challenges, renders lithography printing cost-prohibitive for brands seeking short runs or
versioning.

3. Gravure
Gravure printing engraves designs onto metal cylinders. Each cylinder corresponds to a
specific color, and the printing machine meticulously applies ink, slowly generating a
high-quality image. Primarily recommended for detailed packaging designs, gravure is a
prevalent choice for food products packaged in flexible materials.

Gravure superior image quality and durability give it an advantage in ultra-high volume
print jobs where lithography and flexography would be slower and prone to reduced
image quality over time. Strategic collaboration with a reliable custom packaging
supplier enables production at high speed and low running costs, all without
compromising quality.
Gravure printing presents challenges for projects with low print quantities, as its setup
can be relatively expensive. The setup process for gravure print jobs is time-intensive,
often spanning weeks and incurring costs in the tens of thousands of dollars.
Consequently, gravure proves most effective for projects that involve millions of units
with minimal changes to graphics or text copy. Brands seeking versatility or those not
producing packages in large volumes may find digital printing to be a more cost-effective
and flexible alternative.

4. Digital printing
Digital printing has rapidly gained traction in product packaging, evolving and improving
swiftly compared to traditional methods such as flexo, offset, and gravure. While
relatively new, digital printing, particularly inkjet technology, is becoming a mainstream
choice due to its faster speeds, lower running costs, and enhanced print quality.
 Digital printing’s versatility extends across various products and surfaces, with
particular prominence in corrugated packaging and folding cartons. Once considered
as complementary technology to conventional printing methods, digital printing has
now emerged as a viable mainstream alternative for short-,medium-, and long-run
packaging. In lower quantities, digital printing proves more cost-efficient than its
analog counterparts. Some printers offer hybrid flexographic/digital printing options,
combining of precision of flexo with the variability of digital printing. Notably,
digital printing excels in creating versioned images, variable data, and personalized
packaging-embracing trends that have reshaped the packaging landscape. Digital
printing systems like the HP indigo digital press showcase extraordinary quality on
diverse packaging, including shrink sleeves and labels. The technology enables mass
customization, versioning, serialization, and efficient unique coding, providing brands
with cost-effective solutions for tailored packaging.
While digital printing excels in flexibility and efficiency for shorter runs, it may not
match the unit economics of analog printing technologies in very long runs, ranging
in the hundreds of thousands or millions. For extensive print quantities, flexo,
gravure, and litho may offer more economically viable alternatives. The reliance on
combinations of tiny ink dots makes achieving a perfectly matched, smooth color
challenging in digital printing. Brands that prioritize near-perfect color matching for
logos or other brand elements may opt for other packaging print methods to ensure
precise color reproduction. Understanding these trade-offs becomes crucial for brands
seeking the optimal balance of packaging costs, customization, and print quality.

5. Screen printing
True to its name, screen printing creates design using a woven silkscreen. Specific areas
of the fabric are coated with a non-permeable material, leaving the rest open for ink
application. Since the printing surfaces do not need to be flat, the method adapts to a
diverse range of materials. This includes paper, fabric, glass, and metal, making it a
versatile choice in the printing landscape
 Screen printing distinguishes itself by being best suited for small-scale jobs, offering a
cost-effective solution with relatively low setup costs. Its adaptability to non-flat surfaces
makes it suitable for various materials, providing flexibility in design and applications.
While screen printing proves economical for smaller projects, its production speed is not
optimal for large-scale businesses. The methods relatively slow production time may
pose challenges for heavy-volume requirements. In such cases, opting for offset
lithography, flexography, or gravure printing might be more conductive to meeting the
demands of larger production quantities.

Packaging and Printing Done the Right Way

Each packaging printing technique brings its distinct advantages and challenges. There is
no one-size-fits-all solution, and the key lies in understanding how each method operates to
determine the best fit for your business. This knowledge empowers your brand to make informed
decisions aligned with your specific packaging requirements, whether you prioritize cost
efficiency, intricate design details, or production speed. Should you find yourself navigating the
complexities of packaging printing, consider consulting with experts in the field. Meyers has a
team of seasoned professionals ready to cater to your unique printing needs. Talk to our experts
and start your journey to compelling custom packaging solutions. Discover the most fitting
solution for your business, ensuring that your packaging not only meets industry standards but
also stands out in a competitive market.