Understanding Litho vs Flexo Print on Custom Mailers

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    When ordering a branded mailer from TerraBoard®, it will be printed using either lithographic (Litho) or flexographic (Flexo) printing. Several factors determine the print type. Here's a brief overview of each method:

    Lithographic Printing (Litho):

    An offset printing method where ink is transferred from a metal plate to a rubber blanket, then applied to the substrate. Litho printing is done on a flat sheet prior to die-cutting and conversion. It delivers high resolution output and is ideal for detailed graphics on high-end mailers.

    Pros

    Cons
    • High print quality: Excellent for detailed graphics and fine text
    • Color Consistency: Greater color control and registration

     
    • Higher cost: High ink costs and higher labor/production costs

     

     

     

    Flexographic Printing (Flexo):

    A direct printing method using flexible plates and fast-drying inks. Ink is applied directly from the plate to the substrate in a single process, integrated with folding and converting equipment. Flexo is best for simple graphics with two colors or less and large-volume runs.

    Pros

    Cons
    • Quick turn time: Because everything is produced in a single process, the turn time is often faster
    • Water Based inks: More environmentally friendly
    • Color limitations: Less precise color control and registration

     

     

     

     

    Decision Criteria: Litho vs. Flexo

    Criteria

    Lithographic (Litho)

    Flexographic (Flexo)

    Print Quality

    Superior detail, sharp images

    Good for bold colors and simple designs

    Color Complexity

    Handles complex color builds and graphic detail

    Limited to spot colors and basic designs

    Inline Integration

    Requires separate printing, cutting and converting steps

    Mailers are printed and converted in one process

    Cost Efficiency

    Good for all volumes when high quality print is necessary

    More economical for large runs

    Best Use Case

    Premium mailers with complex graphics

    Bulk mailers with simple graphics

     

    Additional Decision Factors for Litho vs. Flexo Printing

    Several operational and design-related factors influence the decision between litho and flexo printing methods:

    • Equipment Compatibility:
      Certain mailer styles and sizes may require conversion on specific machines that lack flexo capabilities. In such cases, litho printing is required.
    • Order Quantity:
      Flexo printing is generally used for high-volume production runs. At TerraBoard®, flexo is typically used when the custom order quantity exceeds 10,000 mailers.
    • Print Coverage:
      Extensive ink coverage, such as flood coating (full coverage) or designs that bleed over seams and edges, requires litho printing.
    • Color Requirements:
      Litho is required for designs involving more than two colors or complex color builds, as our flexo capabilities are limited to basic two spot colors.
    • Visual and Brand Impact:
      Litho is used for high-end mailers requiring premium print quality and detailed graphics.  Flexo print is better for cost-effective production of large quantities with simple, bold designs.

    Selecting between litho and flexo print depends on a range of factors including design complexity, production volume, turnaround time, and budget. By understanding the strengths and limitations of each method, we can work with our customers to make informed choices that align with their branding goals. At TerraBoard®, our team is ready to guide you through this process to ensure the most efficient, cost-effective, and visually impactful solution for your mailer project.

    Want to Upgrade the Shipping Experience Without Sacrificing Scale?

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    Call our customer service team at 1-502-810-1255 or Submit a contact form

     

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