Sourcing guide
Custom printing on corrugated boxes
Printed boxes turn packaging into a branding tool. Whether you need a simple logo on a shipping box or full-color graphics on a retail-ready carton, understanding print methods, costs, and file requirements helps you get the results you want and avoid expensive do-overs.
Print methods for corrugated
There are three main ways to print on corrugated board. Each has different quality, cost, and minimum requirements. The right choice depends on what you need the box to look like and how many you need.
Flexographic (flexo)
The most common print method for corrugated. Uses flexible rubber or photopolymer plates to transfer ink directly onto the corrugated surface. Available on most box plants and integrated into the corrugating or converting line.
Colors
1–4 spot colors (some presses handle 6)
Print quality
Good for logos, text, and simple graphics. Not photographic quality.
Setup cost
$150–$300 per plate (one plate per color)
Best for
Shipping boxes, RSC cartons, master cases any box that needs branding without retail-shelf graphic quality.
Typical minimums
Typically 500–2,500 boxes depending on supplier.
Lithographic lamination (litho-lam)
High-quality graphics are printed on a separate paper sheet using offset lithography, then laminated onto the corrugated board before die-cutting. Produces photo-quality, full-color results on corrugated.
Colors
Full CMYK + spot colors
Print quality
Excellent. Photo-realistic graphics, fine detail, premium finish.
Setup cost
$500–$2,000+ for plates and lamination setup
Best for
Retail-ready packaging, point-of-purchase displays, premium e-commerce mailers, brand-forward unboxing experiences.
Typical minimums
Typically 1,000–5,000+ boxes.
Digital printing
Inkjet or toner-based printing applied directly to the corrugated surface or a pre-laminated sheet. No plates required, so setup costs are minimal. Quality continues to improve as equipment advances.
Colors
Full CMYK
Print quality
Good to very good. Improving rapidly. Some systems rival litho quality.
Setup cost
Minimal — no plate fees. Higher per-unit cost.
Best for
Short runs, prototypes, versioned packaging, seasonal or promotional items, test orders under 500 units.
Typical minimums
As low as 1 box for some suppliers.
Artwork and file requirements
Providing the right artwork upfront saves time and avoids reprints. Here is what most corrugated printers need from you.
File format
Vector artwork (AI, EPS, or high-resolution PDF) is preferred. Raster images should be 150–300 DPI at actual print size. For flexo, 150 DPI is often sufficient.
Color specification
Specify Pantone (PMS) colors for flexo printing. CMYK for litho and digital. RGB files need to be converted colors will shift.
Bleed and safety
Allow at least 1/4 inch bleed beyond the trim line and keep critical content at least 3/8 inch inside the fold/cut lines. Corrugated converting has wider tolerances than commercial printing.
Dieline / structural file
Your supplier should provide a dieline a CAD template showing all fold lines, cut lines, and print panels. Design your artwork on this template to ensure registration.
Registration tolerance
Flexo printing on corrugated has a typical registration tolerance of ±1/8 inch. Avoid designs where tight registration is critical such as hairline borders that align with fold lines.
Tips for getting the best print results
- Request a printed sample or strike-off before approving a full production run. Colors on corrugated look different than on a monitor or coated paper.
- Keep designs simple for flexo large solid areas, bold text, and spot colors reproduce best. Fine gradients and small text can be problematic.
- Use white or kraft linerboard strategically. Printing on white liner gives cleaner colors. Kraft shows through under lighter inks.
- Ask your supplier whether they print pre-print (on the liner before corrugating) or post-print (on the finished board). Pre-print offers better quality but higher minimums.
- Budget for plate and die costs on first orders. These are one-time charges repeat orders only pay for production.
- Consider digital printing for your first run if volume is low. You can switch to flexo once you confirm the design and scale up.
Find a printer
Find suppliers with printing capabilities
Browse the supplier directory to find corrugated box manufacturers and converters with flexo, litho, or digital printing capabilities.