Digital print vs screen print: the smart choice for packaging in Ireland

You’ve designed the perfect packaging. The colours are spot-on, the typography sings, and your product will absolutely pop on the shelf. Then comes the question that determines whether your project stays on budget and on schedule: digital print or screen print?

It’s not a simple answer, and anyone who tells you otherwise is probably trying to sell you the only method they offer. The truth is, both technologies have their place in modern packaging production. The key is understanding which method serves your specific needs, and that’s precisely what we’re unpacking today.

This guide will walk you through the practical differences between digital and screen printing for packaging, focusing on what actually matters to Irish brands: cost, quality, turnaround times, and suitability for different applications.

Understanding the fundamental difference

Before we dive into comparisons, let’s establish what we’re actually comparing. The distinction between these two methods is more than just technical – it fundamentally affects how your project unfolds.

How screen printing works

Screen printing (also called silk screen printing) is a traditional method that’s been around for centuries. The process involves creating a mesh screen for each colour in your design. Ink is forced through the screen onto your substrate using a squeegee. Each colour requires a separate screen, and the substrate must pass under each screen sequentially to build up the full image.

According to the Speciality Graphic Imaging Association, screen printing remains one of the most versatile printing methods, particularly for textiles and certain packaging applications.

The setup process is labour-intensive. Screens must be created, aligned precisely, and tested before production begins. However, once everything is dialled in, screen printing can run at impressive speeds for large volumes.

How digital printing works

Digital printing takes a fundamentally different approach. Your design file goes directly from computer to printer, with no screens, plates, or physical setup required. Modern digital printing technology uses inkjet or toner-based systems to apply ink directly to the substrate.

As Dr Sarah Mitchell, a packaging technology researcher, explains: “Digital printing has eliminated the economic penalty of short-run production, fundamentally changing how brands approach packaging design and testing”.

There’s essentially no setup time. You can print one unit or one thousand with the same per-unit efficiency. This flexibility has transformed packaging production for brands of all sizes.

The cost equation: when each method wins

Let’s address the elephant in the room: money. The cost comparison between digital and screen printing isn’t straightforward because it depends entirely on your quantity and complexity.

Screen printing economics

Screen printing has high upfront costs but low per-unit costs at volume. You’re paying for screen creation, setup time, and colour matching, expenses that remain relatively fixed whether you print 100 or 10,000 units.

Here’s the typical break-even: screen printing becomes cost-effective somewhere between 1,000 and 5,000 units, depending on the complexity of your design and the number of colours. Below this threshold, you’re essentially subsidising expensive setup costs across too few units.

For Irish packaging projects requiring tens of thousands of identical units, screen printing often delivers the best value. The per-unit cost drops significantly as volume increases.

Digital printing economics

Digital printing inverts this equation entirely. Setup costs are minimal or non-existent, but per-unit costs remain relatively stable regardless of quantity. Your first print costs roughly the same as your thousandth.

This makes digital printing unbeatable for short runs, typically under 1,000 units. According to Smithers research, digital printing has captured significant market share in packaging specifically because brands increasingly value flexibility over volume discounts.

At McGowans Print, we help Irish brands run the numbers for their specific project. Sometimes the answer is clear-cut; other times, factors beyond pure cost determine the best choice.

Quality and finish: comparing the output

Both methods can produce excellent results, but they achieve quality in different ways and excel at different applications.

Screen printing quality

Screen printing delivers vibrant, opaque colours with excellent durability. The ink sits on top of the substrate rather than absorbing into it, creating a tactile quality that digital printing struggles to match. Colours can be incredibly vivid, and speciality inks, metallics, fluorescents, glow-in-the-dark,  are readily available.

For packaging that requires specific Pantone colour matching, screen printing traditionally held the advantage. You’re mixing actual ink to precise specifications rather than relying on a printer to approximate colours using CMYK or extended gamut printing.

The tactile quality matters particularly for premium packaging where the physical experience of unboxing contributes to brand perception.

Digital printing quality

Modern digital printing quality has improved dramatically. High-end systems now rival screen printing for colour accuracy and detail reproduction. Where digital truly excels is in complex designs with gradients, photographic elements, or numerous colours.

Because there’s no physical screen limitation, digital printing handles intricate details beautifully. Fine text, subtle gradients, and photographic images reproduce more accurately than screen printing can achieve. Variable data printing – where each printed piece differs, is only possible with digital methods.

The finish tends to be smoother, with ink absorbed into or bonded with the substrate rather than sitting atop it. For many modern packaging applications, particularly those featuring photography or complex graphics, this works perfectly.

Turnaround time: the speed factor

In Ireland’s fast-moving business environment, timing often trumps other considerations. This is where the two methods diverge dramatically.

Screen printing timeline

Screen printing requires significant setup time. Screens must be created for each colour, typically taking several days. Then there’s colour matching, test runs, and adjustments. From artwork approval to finished product, expect at least one to two weeks for screen printed packaging, often longer for complex jobs.

Rush jobs are possible but expensive. You’re paying to jump the queue for screen creation and production time. For established packaging with existing screens, reprints can be quicker, but first-time projects invariably take time.

Digital printing speed

Digital printing operates on a completely different timeline. At McGowans Print in Dublin, we pride ourselves on fast turnarounds for digital packaging projects, with timelines tailored to each project’s needs.

This speed advantage makes digital printing invaluable for:

The ability to iterate quickly – printing a small batch, gathering feedback, refining, and re-printing, is only practical with digital methods.

Substrate compatibility: what can you print on?

Both methods can print on various materials, but they have different strengths and limitations.

Screen printing substrates

Screen printing works brilliantly on textiles, plastics, glass, metal, and wood. The method is particularly well-suited to non-porous surfaces and unusual materials. If you’re printing on bottles, promotional items, or speciality packaging materials, screen printing often provides more reliable results.

The ink adhesion tends to be excellent because you’re essentially pushing ink through a screen onto the surface with considerable pressure. This mechanical process creates strong bonds with challenging substrates.

Digital printing substrates

Digital printing has expanded dramatically in substrate compatibility. Modern systems handle paper, cardboard, certain plastics, vinyl, fabric, and more. For large format applications, digital printing dominates – building wraps, posters, and display graphics are almost exclusively digitally printed now.

According to the Digital Packaging Alliance, advances in digital ink chemistry and printer engineering have expanded substrate options significantly.

However, some speciality substrates still favour screen printing. Very smooth or non-porous materials can be challenging for digital systems, though this limitation narrows yearly as technology improves.

Design flexibility: where creativity meets practicality

Your design ambitions might dictate which method suits your project.

Screen printing design considerations

Screen printing imposes certain practical limitations. Each colour requires a separate screen, which affects both cost and complexity. Designs with dozens of colours become prohibitively expensive. Gradients and photographic elements can be challenging because you’re working with solid ink applications.

However, for bold, graphic designs with solid colour blocks, screen printing excels. Think iconic brand packaging with strong, simple graphics. The method rewards designs that embrace its constraints rather than fighting against them.

Digital printing design freedom

Digital printing removes most design constraints. Print one colour or one hundred, the cost difference is negligible. Gradients, photographs, and complex graphics are handled identically to simple designs. Variable data printing allows personalisation or versioning across a single print run.

This freedom enables approaches impossible with traditional methods. Test multiple packaging variations simultaneously. Create regional versions with localised graphics or text. Print completely different designs in a single production run.

At McGowans, we’ve seen Irish brands use this flexibility to revolutionise their packaging strategy, moving from one-size-fits-all designs to targeted, audience-specific packaging.

Environmental considerations

Sustainability increasingly influences packaging decisions for Irish brands. Both methods have environmental impacts worth considering.

Screen printing environmental impact

Screen printing uses more chemicals in the setup process, screen preparation, cleaning, and ink mixing all involve solvents and cleaners. Screens themselves have a finite lifespan and must be disposed of eventually. Colour matching can result in excess ink waste.

However, at high volumes, the per-unit environmental cost decreases. The efficiency of long runs can offset setup impacts when you’re producing tens of thousands of units.

Digital printing sustainability

Digital printing eliminates screen waste and reduces chemical usage. The on-demand nature means you print exactly what you need, minimising overproduction waste. At facilities like McGowans with solar power, the environmental footprint shrinks further.

Modern digital inks have also improved environmentally, with water-based and low-VOC options becoming standard for many applications.

When to choose screen printing

Despite digital’s advantages, screen printing remains the smart choice for specific scenarios:

• High volume production: Printing 5,000+ identical units? Screen printing’s economics make sense. The setup cost amortises across the volume, and per-unit costs drop significantly.

• Speciality inks and finishes: Metallic inks, fluorescents, or specific tactile effects often require screen printing. The method’s ink versatility exceeds digital capabilities.

• Specific colour matching: When brand colour accuracy is absolutely critical and you’re matching to existing screen-printed materials, staying with screen printing ensures consistency.

• Non-standard substrates: Certain materials still print more reliably with screen methods, particularly very smooth plastics or unusual speciality materials.

• Established packaging with existing screens: If you’re reprinting existing packaging and screens already exist, screen printing can be quick and cost-effective.

When to choose digital printing

Digital printing is the smart choice for:

• Short runs and testing: Anything under 1,000-2,000 units typically favours digital. The economics work in your favour, and you avoid overproduction risk.

• Tight timelines: Need packaging in days rather than weeks? Digital printing’s speed advantage is insurmountable.

• Design complexity: Photographic elements, gradients, or dozens of colours? Digital handles complexity without cost penalties.

• Personalisation and versioning: Creating regional variations, personalised packaging, or test designs? Only digital makes this practical.

• Sustainable production: Eliminating overruns and reducing waste aligns with environmental commitments.

• Iterative design process: Testing, gathering feedback, and refining? Digital’s flexibility enables true iteration.

• The hybrid approach: best of both worlds

Here’s where it gets interesting: you’re not locked into one method forever. Many successful Irish brands use a hybrid strategy that leverages each method’s strengths.

Start digital, scale to screen

A common approach is prototyping and testing with digital printing, then moving to screen printing once you’ve validated designs and have volume projections. This minimises risk while optimising costs long-term.

Print 500 units digitally to test market reception. If the product succeeds and you’re ordering 10,000 units quarterly, transition to screen printing for better per-unit economics.

Use both for different applications

Your primary packaging might be screen printed at volume, while limited editions, seasonal variations, or regional versions use digital printing. At McGowans Print, we help Irish brands develop multi-method strategies that optimise across their entire packaging portfolio.

Making the decision for your Irish brand

The digital print vs screen print question doesn’t have a universal answer. The right choice depends on your specific circumstances: quantity, timeline, design complexity, budget, and long-term production plans.

Consider these questions:

• How many units do you need? Under 1,000 almost always favours digital; over 5,000 often favours screen printing.

• How quickly do you need them? Urgent timelines dictate digital; planned production allows screen printing.

• How complex is your design? Photographic or gradient-heavy designs suit digital; bold graphics with solid colours suit screen printing.

• Will you need variations or personalisation? This requires digital printing.

• What’s your long-term volume? Testing with digital then scaling to screen printing combines flexibility with economics.

At McGowans Print, we don’t push a single solution. We evaluate your specific requirements and recommend the method, or combination of methods – that genuinely serves your needs best.

The wrap up

The digital print vs screen print question comes down to matching technology to requirements. Screen printing excels at high-volume production with bold designs, offering vibrant colours and specialty finishes. Digital printing dominates short runs, complex designs, and tight timelines whilst enabling personalisation and sustainable on-demand production.

For Irish brands, the choice increasingly involves both methods at different stages or for different applications. Start with digital to test and iterate, then scale to screen printing if volumes justify it. Use screen printing for core packaging and digital for seasonal variations or regional versions.

The technology landscape continues evolving. Digital printing capabilities expand yearly, pushing the volume break-even point higher. Screen printing improves in speed and efficiency. Understanding both methods’ strengths ensures your packaging strategy remains optimised as your brand grows.

Still weighing up digital vs screen print for your Irish packaging project?

Contact McGowans Print for expert guidance.

We’ll review your specifications, run the numbers, and recommend the approach that delivers the best combination of quality, cost, and timeline for your specific needs.

Request a quote and samples today to see both methods’ output for yourself.

Frequently asked questions

Q: Is digital printing cheaper than screen printing?
A: It depends entirely on quantity. Digital printing is cheaper for short runs (typically under 1,000-2,000 units) because there are no setup costs. Screen printing becomes more economical at higher volumes (5,000+ units) because setup costs spread across many units, reducing per-unit price significantly. Calculate costs for your specific quantity before deciding.

Q: Which method produces better quality packaging?
A: Both methods produce excellent quality but excel at different things. Screen printing delivers more vibrant, opaque colours and better tactile finishes, ideal for bold graphic designs. Digital printing handles complex designs, photographs, and gradients more accurately. For most modern packaging applications, quality differences are minimal, the right choice depends on your specific design rather than absolute quality.

Q: How long does each printing method take?
A: Digital printing typically delivers in 24-48 hours for most packaging projects, with same-day possible for rush jobs. Screen printing requires 1-2 weeks minimum for new projects due to screen creation and setup time. Reprints using existing screens can be faster, but first-time projects always need more lead time.

Q: Can I change designs easily with screen printing?
A: Design changes with screen printing require creating new screens, which adds cost and time. Each colour change or design modification means new screen expenses. Digital printing allows design changes without additional setup costs, making it ideal for testing variations, seasonal packaging, or personalised versions. This flexibility is digital’s key advantage.

Q: Which method is more environmentally friendly?
A: Digital printing generally has environmental advantages: no chemical screen preparation, exact quantity printing reduces waste, and lower energy usage per unit for short runs. Screen printing uses more chemicals in setup but can be more efficient at very high volumes. At McGowans’ solar-powered facility, both methods’ environmental impact is reduced. The most sustainable choice often depends on printing exactly what you need rather than overproducing.

Q: Do I need to choose one method permanently?
A: Absolutely not. Many successful Irish brands use both methods strategically. Start with digital printing to test designs and gauge demand, then transition to screen printing once you’ve validated the product and have consistent volume requirements. Use screen printing for core packaging and digital for limited editions, seasonal variations, or regional versions. A hybrid approach often delivers the best overall value.