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Flexo vs. Digital vs. Rotogravure: Printing Poly Bags
How your bag is printed affects its color range, its per-unit cost, and its minimum order — so the right method depends on your artwork and your volume. Knowing the three main options helps you get the look you want at the price you expect.
Here’s how flexo, digital, and rotogravure compare for custom bags.
Flexo: economical spot color
Flexographic printing uses plates to lay down solid spot colors, typically one to eight. It’s economical at volume for logos and simple designs, holds Pantone colors precisely, and is the workhorse for clear poly zip bags. It carries a plate cost, so it favors larger runs and stable artwork.
Digital: full color, low minimums
Digital printing needs no plates, so it’s ideal for full-color and photographic artwork, short runs, and frequent design changes. Minimums are lower and setup is fast, which makes it perfect for launches, seasonal designs, and testing before you scale to a longer run.
Rotogravure: premium high-volume color
Rotogravure uses engraved cylinders to produce the richest, most consistent full-color print at high volume — the method behind premium retail pouches. Cylinder costs make it a high-volume choice, but for large runs it delivers the best color at the lowest per-unit cost.
| Method | Best for | Minimums |
|---|---|---|
| Flexo | Spot-color logos, clear poly | Moderate |
| Digital | Full color, short runs, testing | Low |
| Rotogravure | Premium high-volume pouches | High |
Start digital to launch and iterate, then move a proven, high-volume design to flexo or rotogravure for the lowest per-unit cost.
Send your artwork and volume and we’ll recommend the printing method that fits — with a free mockup within one business day.
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