Unlocking the Benefits of Direct-to-Package Printing: A Guide to Choosing the Right Solution

In today’s fast-paced and competitive market, packaging is more than just a product container — it is a critical tool for branding, customer engagement, and operational efficiency. Direct-to-package printing is revolutionizing how businesses approach packaging, offering unparalleled flexibility, speed, and customization.

When considering investing in an in-house solution, explore these insights into the benefits and key factors of selecting the right system.

The Benefits of Direct-to-Package Printing

• Enhanced Customization Direct-to-package printing enables businesses to produce high-quality, full-color graphics, variable data, and personalized messages directly onto packaging materials. This capability supports seasonal promotions, limited-edition designs, or targeted campaigns, helping brands stand out and connect with their audience.

For example, a Southeast Asian company leveraged AstroNova’s direct-to-package T3-OPX printer to add logos and custom artwork directly onto food packaging, meeting the demands of brand-conscious retail customers. Similarly, direct-to-package printing can create memorable unboxing experiences by adding customer names or regional-specific designs—a strategy famously employed by a global soft drink manufacturer with their personalized holiday labels.

• Streamlined Operations By bringing printing in-house, companies can eliminate the need for third-party suppliers and reduce lead times. This flexibility facilitates on-demand printing, minimizes excess inventory, and allows for faster product launches.

A leading U.S. bakery and delicatessen packaging manufacturer integrated the T3-OPX into their operations to handle custom print jobs without limitations on shapes, sizes, or minimum order quantities. This enabled faster fulfillment and greater adaptability to customer needs.

• Cost Savings Investing in an in-house printer reduces dependency on external vendors, cutting costs associated with outsourcing, storage, and obsolete inventory. Systems with built-in cost calculators, such as the T3-OPX, provide businesses with tools to analyze and optimize printing expenses.
• Sustainability and Efficiency Modern direct-to-package printers, like the MULTI 800, support eco-friendly initiatives through water-based inks and reduced material waste. These features align with growing consumer demand for sustainable practices while maintaining production efficiency.

Direct-to-package printing also addresses top megatrends in packaging redesign: sustainability, brand experience, and supply chain agility. A division of a large packaging conglomerate integrated the T3-OPX to offer sustainable, customizable solutions while meeting rapid fulfillment demands in medium to short-run quantities.

Key Attributes to Consider

When selecting a direct-to-package printing solution, businesses should evaluate these critical attributes:

• Print Technology: Advanced technologies, such as water-based inkjet, deliver high-quality results.
• Ink Type: Pigment and dye inks should be chosen based on durability and color vibrancy requirements.
• Print Speed and Resolution: The system should balance speed with sharp image quality.
• Maximum Print Width and Height: The printer must accommodate the dimensions of the packaging being printed.
• Handling and Automation: Features like automatic height calibration, tilt adjustments, and pressure configuration simplify operations and improve accuracy.
• Software Capabilities: Robust print management software ensures seamless integration and operational control.
• Scalability: The printer should handle variable data printing and diverse materials as the business grows.

Leading Direct-to-Package Solutions

AstroNova offers two industry-leading direct-to-package printers designed to meet diverse business needs:

MULTI 800

The MULTI 800 is an entry-level digital printer for professional packaging, paper bags, and corrugated box production. Its Industry 4.0 readiness and water-based ink technology make it an excellent choice for eco-conscious businesses.

Applications: Corrugated boxes, food packaging, shopping bags, and more

Key Features:

• Automatic suction-cup feeder
• Belt with vacuum table
• Dryer module for rapid processing
• Print speed of up to 27 m/min
• Maximum print width of 430 mm

The MULTI 800’s versatility and user-friendly interface enable businesses to handle a variety of packaging needs efficiently and sustainably.

T3-OPX

The T3-OPX is a next-generation direct-to-package printer for wide-format applications and high-speed production. Its robust capabilities make it ideal for larger businesses or those requiring late-stage customization.

Applications: Postcards, boxes, wooden planks, blister envelopes, and more

Key Features:

• Automatic height calibration for rapid changeovers
• Print width up to 11.7” (297 mm)
• Economical CMYK ink cartridges
• Built-in cost calculator and remote diagnostics
• Production-grade design for 24/7 operation

The T3-OPX’s impact can be seen globally. A European paper bag printer successfully transitioned from traditional offset printing to digital by integrating the T3-OPX with a unique conveyor and feeding solution. Similarly, a wooden packaging company used the T3-OPX to meet increasing customer requests for detailed, high-quality branding on their products.

Take the Next Step: Direct-to-Package Printing

Direct-to-package printing is the future of packaging solutions. If the goal is greater customization, cost efficiency, or sustainability, direct-to-package printing offers transformative benefits for companies aiming to enhance their packaging strategies.

AstroNova’s MULTI 800 and T3-OPX are cutting-edge direct-to-package printing systems that drive operational success.

Learn more, including seeing them in action with virtual online demos here.