Carton Printing & Packaging: Challenges and Solutions | InkJet, Inc.
Carton packaging is becoming a popular option for many products. According to stats from Reportlinker.com, the folding carton packaging market is expected to reach $177.25 billion globally by 2027, growing at a compound annual growth rate of 4.62%. While that is great news for the carton packaging industry, it’s not so great for factory managers who have to print codes and other essential data on those packages, which are often porous and uneven. These managers and others must deal with the printing challenges posed by carton packaging to achieve optimal results. The table below lists carton printing & packaging challenges as well as some possible solutions.
Carton Printing & Packaging: 10 Challenges and Solutions
Issue
Challenge
Solution
1) Ink Adhesion
➖ Porous carton surfaces make it challenging for inks to adhere properly.
➕ Use inks formulated explicitly for carton materials or pre-treatment processes to improve ink adhesion.
2) Color Consistency
➖ Color consistency can be tricky between batches or print runs.
➕ Set up a color management system, use standardized color profiles, and calibrate printers to ensure color consistency.
3) Bleeding and Smudging
➖ Smudging or bleeding can happen if the carton material absorbs ink.
➕ Use quick-drying inks and integrate proper drying mechanisms into the printing process.
4) Die Cutting Precision
➖ Die-cutting carton packaging can be tricky, leading to misalignment or irregular shapes.
➕ Invest in high-precision die-cutting equipment and conduct testing to ensure accurate alignment and shape conformity.
5) Folding and Creasing Issues
➖ Folding and creasing cartons can cause cracking or distortion of printed elements.
➕ Choose flexible carton materials and adjust printing settings to minimize stress on the printed areas during folding and creasing.
6) Printing on Irregular Surfaces
➖ The surface of carton packaging can be uneven or textured, making printing challenging.
➕ Use printing methods for uneven surfaces, such as flexography, and adjust parameters to accommodate surface variations.
7) Moisture and Humidity
➖ Moisture and humidity can affect the quality of printing on carton packaging.
➕ Maintain optimal humidity levels in the printing area and store carton materials in a controlled environment before printing.
8) Regulatory Compliance
➖ Regulatory requirements for barcodes, safety symbols, and legal text can be challenging to meet.
➕ Plan the design layout to meet regulations, conduct regular reviews to ensure compliance, and consult with regulatory experts.
9) Cost Constraints
➖ Budget limitations can impact the choice of printing methods and materials.
➕ Optimize printing processes for efficiency, use cost-effective printing methods, and negotiate bulk discounts.
10) Prototyping
➖ Creating accurate prototypes for testing can be time-consuming and costly.
➕ Use digital prototyping tools and work with printing providers to reduce prototyping time and cost.
Finding the Right Carton Printing & Packaging Solution
When considering what printer to use, choosing a device that can accommodate the porous nature of most cartons and print at a high enough quality to create scannable codes and other information on darker surfaces is essential. Thermal inkjet printers (TIJ) and high-resolution case coder printers stand out from the rest in this regard.
InkJet, Inc. has a range of thermal inkjet printers and high-resolution case coders to meet your carton printing and packaging needs. Each technology carries distinct application specialties, specifications, and cost factors. The table below lists our various hardware options and notes their general specifications.
InkJet, Inc.’s Carton Printing Systems
Coding Technology
Operating Method
System Options
Maximum Resolution and Print Height
Maximum Marking Speed
Cost Factors
Thermal Inkjet Printer
Uses heat to pressurize and eject ink droplets toward the substrate
Anser U2 Models
400 x 300 DPI (height varies by model)
76.2 m/min
Low unit cost, moderate consumable cost
Anser A1
600 x 600 DPI at 1” height (2” height with stitched print heights)
300 m/min with HP cartridges, 150 m/min with IUT cartridges
Moderate unit cost, moderate consumable cost
Anser X1
600 x 600 DPI at 1” height (2” height with stitched print heights)
300 m/min
Moderate unit cost, moderate consumable cost
Hi-Res Case Coder
Propels oil-based ink droplets to create stark codes
Precision Series 18mm & 72mm
180 DPI at 18 mm height or 72 mm height
Low to moderate speed
Moderate unit cost, low consumable cost
You can print on carton packaging without issues by selecting the right devices. Modern TIJ and case coding printer models can perform almost any task, from creating scannable codes on shipping boxes to putting an expiration date on egg cartons.
High-Quality Inks for Carton Packaging Requirements
But it’s not just about printers. Your ink also needs to be suitable for carton packaging requirements. InkJet, Inc. has produced a range of high-quality inks for over 30 years. Our comprehensive catalog contains numerous formulas to better meet your printing needs.
We offer many formulas with special properties, including:
Superior substrate adhesion
Ultra-quick dry times
Sunlight resistance
Fade and rub resistance
Soft/hard pigmentation
We also carry aftermarket formulas for today’s most popular printers. Our aftermarket options are more affordable than their OEM counterparts but perform just as well, if not better.
If you still have questions about carton printing & packaging, InkJet, Inc.'s experts can help you decide which device is right for you. To ensure you are well-equipped for all production needs, we offer industry-leading guidance, answer all your questions, and even perform testing and validation services.
For more information about printing on carton packaging, contact InkJet, Inc. online or by phone at 1(800) 280-3245.
