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Custom boxes can be modified in any way a brand wants, the customization part is literally in the name. From their shape to the outer print, every aspect of bespoke packaging can be altered to fit any product or design choices. This flexibility is the reason why these boxes are preferred by businesses and have become the new standard across multiple sectors, including the cigar industry.

When it comes to the visual appeal of a product, these boxes play a vital role. However, there isn’t any set printing technique that is used across the industry. There are multiple methods to imprint designs on boxes, such as custom cigar packaging. Each has its own specific use cases, benefits, and drawbacks. With that in mind, in this article, we will discuss the top 5 printing techniques for custom cigar boxes.

Top Printing Methods for Custom Cigar Packaging

The technique used for custom packaging plays a vital role in its cost and how good the final result is. Some methods to imprint designs on bespoke cigar boxes are costly for a small batch, while certain ones are cheap to print in small quantities. On top of that, certain techniques fulfill the sustainability requirements for current standards but have their own setbacks.

The reason we are discussing these methods is that brands can choose which one is best for their product packaging. Understanding them allows businesses to make an informed decision. The following are the best printing techniques to print custom cigar boxes:

1-      Offset Printing

It is one of the most commonly used methods in the packaging industry. It has more benefits than disadvantages. From being cost-effective to consistent color accuracy, there is a reason offset is preferred by brands. How does this technique work? The ink is transferred from a plate to a rubber blanket, which is shaped as per the design. The blanket is then pressed on the packaging to imprint the visuals.

As for the advantages of this method, the final result is always high quality, as it ensures the box is printed with sharp and vibrant colors with small details being preserved in the final results. On top of that, it offers consistency from the first unit printed to the last. This means that the color shade from the first box is exactly the same as the 500th one that is printed using the offset technique.

In terms of cost, it is very affordable, but only if brands plan to imprint a large batch, which makes it suitable for cigar brands that have a lot of demand in the market. The reason it is expensive for small production runs is that the initial setup cost is just too high.

Given that custom boxes are made with a variety of materials, like cardboard stock, this technique can be used for any of them. Whether it’s cigarette packaging boxes made of any material, this technique can print designs on them.

2-      Digital Printing

This method of printing design on custom cigar packaging is quite new and has been gaining traction in recent years. Unlike the offset technique, this one is very easy to set up, as the ink is directly transferred to the box surface without the need for any printing plate. This makes it very cost-effective, however, only for small production runs. If you plan to imprint designs in large quantities, it will turn out to be very expensive.

On top of that, consistency is a concern with digital printing. While the offset method ensures the colors on the first box are the same as the last one, the digital print loses color accuracy for large batches. This is another reason why it is suitable for small quantities.

Another thing to consider about the digital prints is their turnaround time. Since there is no need to set printing plates and only small batches have to be printed, brands get their order delivered quickly. This method is ideal for businesses that sell cigars in limited quantities.

3-      Flexographic Printing

You can consider this printing method to be a balance between offset and digital. It is a method that can imprint designs on any type of surface, be it plastic, paper, or metallic. Speed and efficiency are what brands get by using this technique. Despite it being affordable for a large batch of custom cigar boxes, its turnaround time is less than the offset technique.

The one advantage of this method that others do not have is its eco-friendliness. It uses water-based inks instead of solvent ones, which makes it quite ideal for brands who want to build a green reputation. However, it is quite ironic to use this technique for cigar boxes, considering the carbon footprint when they are smoked.

  • Fast Production: It allows for high-speed printing, making it suitable for large-volume jobs.
  • Versatile Substrates: It can print on a wide range of materials, from porous surfaces to non-porous ones.
  • Water-Based Inks: Flexography often uses water-based inks, which are more environmentally friendly compared to solvent-based inks.
  • Cost-Effective: It is economical for long runs, as the setup costs are spread out over a larger number of prints.

4-      Matte

This one is not so much a printing technique as it is a finish, however, considering how it works, it does have the same have the same quality as the former. What makes it stand apart from the rest of the techniques is that to have a matte print, businesses have to use either offset or digital methods. Special inks are used to give the cigar packaging the signature muted colors of a matte finish.

Due to its opulent look and feel, this is perfect for high-end labels. On top of that, it can work in tandem with a spot UV finish if you intend to make certain design elements more prominent. You can print designs such as a logo using spot UV on top of a matte print. This created a contrast between the two, which will make the branding element shine even more and grab buyer attention even in a crowded market.

5-      Screen Printing

Screen printing is another one of the methods to print designs on custom boxes. This one is capable of imprinting on many materials. It starts with a mesh screen, which is stretched over a frame. You create a stencil by blocking out parts of the screen, leaving open areas for the design.

Once that’s ready, it’s time for the fun part, which is applying ink. A screen is placed over the material, like paper, and then a squeegee is used to push the ink through the open sections. After that, the design is cured to ensure the ink sticks and the design lasts for a long period of time.

To Wrap Up

The printing method brands choose to print their desired design on custom cigar packaging plays a vital role in the final look. The techniques we have discussed here are some of the best ones that businesses can choose from. Each has its pros and cons. Some are ideal for a large production run, while some are cheaper for printing small quantities. If you still have lingering questions regarding these techniques, then CPP Boxes can be of service. They offer free design support, and their analyst can help you choose the ideal method. Aside from that, they also offer free shipping and a fast turnaround.

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