In this last of the high color corrugated overview in anticipation of drupa 2020, we will look at the “preprint” process of corrugated. As a refresher, this a multi-process method of printing on a top sheet (liner) which is then laminated to the corrugated material. This is currently the most widely used method for printing high color graphics (three or more colors) on corrugated. If you haven’t read the previous articles in the series, in my first article of the year we looked at the recent Karstedt study on high graphics corrugated growth, and in Part 1 of this series, we looked at some analog technologies for corrugated post-print. In Part 2, we looked at digital solutions for post-print.

Prior to the introduction of production inkjet post-print (direct to corrugated) printing solutions for high color graphics, this was and actually still is the primary production process—for obvious reasons. If you recall from previous articles, printing on the soft, dirty, and uneven surface of corrugated is not easy for any direct contact printing process. Offset is pretty much out of the question, but very tightly controlled flexo like Bobst MASTERFLEX-XL THQ and Koenig & Bauer CorruFLEX can work. Which is why printing on a liner or clean smooth paper first and then laminating it to the corrugated has been the process of choice. After all, most printing processes including offset, flexo, gravure, EP, and inkjet print on a variety of papers really well all the time. 

Flexo still has the lion’s share of the market, primarily due to its lower cost and higher productivity. Next in line would be offset, some gravure, up and coming inkjet, and even a little electrophotography (EP). Historically, offset and gravure have been selected to achieve a higher quality than flexo; however, with some of the newer flexo plate and equipment solutions that may no longer be the case. The biggest growth opportunities are expected with inkjet since it is very much in a startup position. According to IT strategies, inkjet for corrugated growth rates between 2018 and 2023 will approach 35% CAGR, while analog will maintain a fairly steady but still attractive 3%.