From design to shelf: optimizing printing for FMCG packaging

Printing may seem like just one step in packaging production, but for food and beverage brands, it’s one of the most critical stages. A misprint, an overuse of ink, or a compliance error can lead to costly reprints, delayed launches, or regulatory headaches. Fortunately, with the right practices, monitoring, and software tools, you can optimize the printing process, reduce costs, maintain quality, and stay compliant with European regulations.

Why Printing Matters

Printing isn’t just about making packaging look good—it’s about cost, quality, sustainability, and brand perception.

Common pitfalls include:

• Overuse of ink or coatings, increasing material costs

• Color inconsistencies across production batches

• Misalignment or registration errors leading to reprints

• Non-compliance with food contact regulations

By understanding the process and integrating smart tools, brands can avoid these mistakes and gain competitive advantages.

Choosing the Right Inks and Coatings

Not all inks are created equal. The choice depends on:

• Material: Cardboard, plastic, glass, or metal substrates all absorb and reflect inks differently.

• Print method: Offset, flexography, gravure, and digital printing each have unique requirements for ink viscosity and density.

• Coatings and finishes: Varnishes, spot UV, and lamination protect packaging and enhance visual appeal but add cost and complexity.

💡 Tip: Selecting the right ink for the substrate and print method can reduce costs by 10–20% while preventing production delays and defects.

How Much Ink is Enough?

Excessive ink isn’t just wasteful—it can create:

• Smudging or bleeding

• Longer drying times

• Material waste and higher energy use

Tools like print coverage calculation software let teams monitor ink usage digitally, ensuring precise application and reducing unnecessary over-inking. For designers, this means they can maintain vibrant colors and quality without overspending.

Quality Control at Every Stage

Ensuring consistent, high-quality prints requires checks before, during, and after production:

• Pre-press: Optimize files, verify resolution, and check spot colors.

• Inline: Monitor color accuracy, registration, and coating application.

• Post-press: Inspect samples, measure coverage, and ensure alignment.

💡 Software can centralize these checks, store records, and alert teams to deviations before costly errors occur.

Key EU Food Packaging Regulations

Food and beverage packaging is heavily regulated in Europe. Key rules include:

1. Food Contact Materials (FCM)

   • EC 1935/2004: Materials must not transfer harmful substances or alter food composition.

   • EU 10/2011: Limits migration of substances from inks, coatings, and plastics.

2. Chemical Safety

   • REACH (EC 1907/2006): Ensures inks and coatings are registered and safe.

   • CLP (EC 1272/2008): Requires proper labeling and hazard communication.

3. Industry Standards

   • ISO 12647: Process control for consistent printing results.

   • Sustainable certifications like FSC or PEFC may affect substrate and ink choice.

💡 Tip: Keep compliance records digital and linked to each SKU for smooth audits and faster regulatory approvals.

Optimizing the Printing Process

Printing costs can be significantly reduced by:

• Centralized workflow management: Keep all approvals, revisions, and feedback in one platform to prevent errors and reprints.

• Batch planning: Group SKUs with similar colors or coatings to minimize changeovers and cleaning times.

• Ink and coating optimization: Use tools to calculate and track coverage, avoiding waste.

• Sustainability integration: Reduce energy, material, and chemical use while maintaining high-quality prints.

Cost Savings Through Packaging Artwork Management

• A European beverage brand reduced ink usage by 15% using print coverage calculation software.

• A snack manufacturer cut reprints by 20% after centralizing artwork approvals online.

• A multinational personal care company avoided costly misprints across hundreds of SKUs by standardizing color profiles and production specs.

These examples show how software, planning, and smart monitoring can deliver tangible cost savings while improving brand consistency.

Best Practices for Brand Managers and Designers

1. Consider print requirements during the design phase to avoid late-stage changes.

2. Standardize color profiles, ink coverage, and file formats across SKUs.

3. Use software tools to monitor ink and coating usage.

4. Track regulatory compliance for every product.

5. Evaluate substrate, print method, and coating options for cost and sustainability.

Conclusion

Printing for food and beverage packaging in Europe is complex but manageable. By combining smart software tools, process optimization, and regulatory knowledge, brands can:

• Reduce printing costs

• Improve quality and brand consistency

• Stay fully compliant with European regulations

• Support sustainability goals

In a competitive market, every print counts, and the right approach can make the difference between a smooth launch and costly delays.