Package Design: Game Changing Digital Print

Brand owners need a cost-effective way to create standout packaging and displays that can meet the demands of today’s dynamic retail environment. With hundreds of millions of packages shipped each year to big box retailers like Walmart and Target, concerns about sustainability, cost-efficiency, and speed-to-market are more relevant than ever. 

 Printers and manufacturers must now respond to pressing questions like: 

• Can this take cost out of the supply chain?

• How can I customize packaging and displays for specific retailers, regions, or promotions?

• Can this demonstrate ROI for every penny spent?

• Can I improve time-to-market while delivering a strong, immersive brand experience?

The pros and cons of offset lithography versus digital printing are well documented. Litho has long been the go-to for consistent, high-quality imagery across long runs and diverse surfaces. Its reliability and output quality are unmatched—until now.

Litho’s drawbacks, including high costs, longer setup times, waste, and lack of variable data capability, have opened the door for digital printing to disrupt the status quo.

Traditional digital printing offered benefits like faster setup and suitability for short runs or prototypes. But historically, it lacked the speed, cost-efficiency, and color consistency needed for broader applications.

That’s changing.

What digital presses once did for traditional print, Bennett’s platform is now doing for large-scale retail displays and packaging.

The company’s digital press is a 6-color, high-speed, direct-to-corrugate system that rivals the speed and quality of litho and flexo. But where it really shines is in the added agility it brings to creative execution.

Sweet continues, “A lot of brands assume digital can’t match colors—but that’s simply not true anymore. We can build nearly any spot color, and once it’s approved, it stays consistent throughout the run—and future reprints.”

That consistency is key for brand integrity, particularly for high-profile retail launches or seasonal campaigns that require precise color matching across materials and runs.

A recent collaboration with Samsung showcased the full potential of Bennett’s digital capabilities. The global electronics brand needed to launch a new product in U.S. stores—fast.

With the product shipping from overseas, timing was critical. Choosing digital over traditional print methods eliminated the need for print plates and reduced setup time drastically.

The job was completed efficiently and with impeccable quality, earning Bennett future opportunities with the tech giant.

“Samsung ships more than 25,000 TVs into the U.S. daily,” says Sweet. “Digital lets us move faster, respond quicker, and reduce materials by eliminating litho labels. That’s a huge step forward in terms of both efficiency and sustainability.”

The implications of this technology stretch far beyond a single project. Today’s brands are under pressure to be faster, more sustainable, and more relevant than ever. Digital print solutions are helping brands:

• Reduce waste and costs by eliminating tooling, overproduction, and storage.

• Increase speed-to-market by minimizing setup and production time.

• Enhance personalization and localization with variable data and customizable runs.

• Maintain consistent quality across every display and package.

• Support sustainability goals through smarter resource use and less material waste.

Sustainability is no longer a bonus—it’s an expectation. Brands that fail to demonstrate environmental responsibility risk losing consumer trust. Digital printing offers a cleaner, more efficient solution that minimizes waste and removes the need for print plates, making it inherently more sustainable.

Bennett’s technology supports direct-to-corrugate printing, eliminating extra layers of material, such as litho labels, and reducing total paper usage. Because it enables on-demand production, brands can avoid overproduction and costly storage while keeping inventory lean. Less waste, fewer materials, and smarter logistics mean a significantly smaller carbon footprint.

Sustainable packaging isn’t just good for the planet—it’s a smart brand move. It builds customer loyalty, strengthens your ESG profile, and helps you comply with growing retailer sustainability requirements.

One of the most exciting advantages of digital printing is the ability to personalize and localize packaging and displays at scale. Traditionally, making multiple versions of the same package—one for each region, demographic, or retailer—was cost-prohibitive. With Bennett’s digital platform, it’s both affordable and fast.

Whether it's printing five display versions for five national retailers or customizing promotional artwork based on geography, digital opens the door to micro-targeted marketing without disrupting production timelines or budgets.

This level of flexibility allows brands to:

• Run A/B tests in-store with different designs

• Personalize campaigns based on consumer behavior

• Support regional promotions or cultural moments

• Boost shopper engagement through localized storytelling

When every version of your packaging feels intentional and unique, shoppers are more likely to stop, interact, and convert.

With the largest and most advanced digital corrugate press in the country, Bennett is helping redefine what’s possible in print. Whether you’re launching a national campaign or a regional promotion, digital gives you the freedom to execute with speed, precision, and confidence.

Ready to explore how Bennett’s digital platform can elevate your brand?

Start a quote today and see what’s possible.