Digital printing is gaining ground in every packaging segment, but analogue presses still dominate most segments in volume terms.
Press optimisation is proving extremely important for the printed packaging industry, offering higher efficiency at all run lengths and reducing the need for skilled workers, according to new research from Smithers, The Future of Package Printing to 2031.
Key figures at a glance
A market picking up speed
After modest growth over the past five years, at a CAGR of 0.9% in value and 1.0% in volume, the printed packaging market is set to accelerate. Value and volume are both forecast to grow at a CAGR of 3.6% between 2026 and 2031.
Why brands are turning to digital
Digital printing systems are now offered for most packaging segments. Some are adapted from other applications, such as wide-format graphics, but most presses on the market are purpose-built for packaging.
Several factors favour digital, in particular its ability to produce high-quality graphics at short and ultra-short run lengths. This suits many of the industry’s needs, as brands and retailers look to engage more directly with consumers.
Labels lead, other segments follow
Digital label printing has a high penetration rate and is considered a mainstream production process. Corrugated is growing in both pre-print and post-print applications, while flexible and carton printing are growing too, albeit from a small base. Penetration is rising across the board, but it remains low in terms of volume.
Most digital packaging presses use water-based inks. The main exception is label printing, where UV inks dominate. UV is also used to some extent in corrugated, typically where the market overlaps with sign and display.
The speed ceiling
Production speeds are still limited by current technology. Most inkjet systems top out at around 100 m/min, though some run faster, while electrophotographic (EP) systems reach around 120 m/min. Monochrome systems can run significantly faster. Productivity can also be boosted by adding print heads, at extra cost, or by reducing resolution, at the expense of quality.
Digital presses are also becoming more automated. A growing number of suppliers now offer register control, colour management, quality control, and system monitoring and maintenance as standard.
Analogue becomes more efficient
Enhanced productivity features are being added to all press technologies. In flexo, developments are typically aimed at improving environmental performance, automation, standardisation, connectivity, control, print quality and short-run economics.
The use of fixed-palette printing is increasing. When combined with extended colour gamut (ECG), it allows most spot colours to be reproduced. This means jobs can be changed rapidly without cleaning inks, anilox rollers and ducts, significantly increasing press efficiency. As a result, analogue equipment is becoming more efficient at shorter run lengths, an important development for the packaging industry as a whole.
Towards the 'lights-out' press room
Robotic handling is being introduced for corrugated and paper/paperboard presses, with several implementations using automated guided vehicles (AGVs) to deliver print media to the press. Other developments include automated make-ready, registration and plate changing, and advanced quality inspection systems.
Most suppliers are introducing presses with increased throughput, allowing converters to produce work more efficiently and with fewer skilled staff. Some companies are even discussing unmanned print production, with ‘lights-out’ manufacturing in the press room considered a realistic future goal.
This article is based on the findings of a newly published Smithers report, The Future of Package Printing to 2031. This comprehensive study takes a deep dive into the printed packaging market. Based on extensive primary research and proprietary analysis, it is an essential guide for print producers, suppliers, investors and market strategists navigating a rapidly changing industry.
