How about the print-making charge in flexible packaging？

Many buyers ask me: how much does printing cost¹ when customizing flexible coffee bags? The answer is—it depends more than you think.

Printing charges include plate or cylinder setup fees², color count³, order volume, material compatibility, and finishing effects. They can affect both upfront and unit costs.

I still remember my first customer who was surprised by the plate charge. He thought printing was like printing on paper. But in flexible packaging⁴, each color and design adds cost—even before the first bag rolls off the line.

What is printing in flexible packaging⁴?

Printing on flexible packaging⁴ isn’t the same as printing on cardboard or labels. It needs to be stretchable, durable, and food-safe.

Printing in flexible packaging⁴ means applying logos, colors, and text directly onto laminated films like PET, PE, or foil, often before the bag is formed.

Dive Deeper

Why printing needs to be flexible

Flexible packaging uses thin, bendable materials—often plastic films or metal foils. These materials expand, curl, or stretch when handled, sealed, or filled.

• Ink must stay bonded to the surface without cracking
• Layers are laminated, so printing may be on inner or outer side
• It must survive heat sealing, rolling, and storage

What gets printed

• Brand name and logo
• Roast origin, flavor notes, date, weight
• Certifications like organic or Fairtrade
• Design artwork and color blocking

Common substrates used⁵

Printing on these films requires special inks and high-speed presses. It’s not just a sticker—it’s integrated into the bag’s identity.

How does packaging printing work?

If you want to understand printing cost¹s, you must first understand how printing is done.

Flexible packaging uses flexo, gravure, or digital printing⁶. Each method has different setup fees², color handling, and suitability for short or long runs.

Dive Deeper

Three main printing methods⁷

1. Flexographic Printing

Used widely in China for medium to large runs.

• Uses flexible rubber plates
• Each color needs a separate plate
• Good for kraft, PE, laminated films

Setup cost per plate: $100–$300
Best for: 3,000+ bags

2. Gravure Printing

High-end quality for very large orders.

• Steel cylinders engraved for each color
• Deep, rich color tones and gradients
• Long-lasting cylinders reused for reorders

Setup cost per cylinder: $400–$1,000+
Best for: 10,000+ bags or major campaigns

3. Digital Printing

No plates needed—great for small batches.

• Ideal for startups or custom SKUs
• Can print variable data (e.g. QR codes)
• Lower upfront, higher per-unit price

Setup cost: $0 (but higher unit cost)
Best for: 1–2,000 bags

Print cost comparison

Each printing method works best at a different scale. For example, digital is ideal for a new coffee brand with 3 SKUs and small volumes. Gravure works well for brands doing supermarket distribution.

Conclusion

Gravure printing will be adapted with plate making fee is charged. Don't worry that the plate making fee only charged one time on condition of no change on sizes or designs in later orders. This printing effect and process is exactly same as mass quantity production.
Honestly the printing effect has very little difference.

Digital printing is more suitable to smaller quantity order. Gravure printing is perfect for. mass production.

If your final aim is long-term and mass quantity purchase, gravure printing is suggested, because it is the most close effect to mass order.

Print-making charges aren’t just about ink—they include tools, color count³s, run sizes, and materials. Whether you're printing 500 or 50,000 coffee bags, understanding the printing method helps you budget wisely and avoid surprise fees.