Printing Methods & Info
Printing Methods & Information
Everything you need to know about custom printing on retail bags — methods, colors, artwork requirements, lead times, and how to choose the right option for your project.
Quick Comparison
| Feature | Digital | Flexographic | Hot Stamp | Screen Print | 4-Color Process |
|---|---|---|---|---|---|
| Colors | Unlimited (CMYK) | 1–3 stock inks | 1 foil color/pass | 1–3 PMS matched | Full CMYK |
| Minimum | 1 case | 5,000–6,000 | 100 bags | 100 bags | 50–100 bags |
| Setup Cost | None | $68–$150/plate | $73–$192/plate | $65/screen | None |
| Print Cost | $0.25/bag/side | $109–$153/M | $147–$309/M | $21–$34/100 | Varies |
| Lead Time | 5–7 days | 2–4 weeks | 10–15 days | 10–15 days | 7–10 days |
| Best For | Short runs, photos, full color | Large runs, economy | Metallic/foil, luxury | PMS match, large areas | Multi-color, tight register |
| Substrates | SOS, Merch, Mailers, Shoppers | Paper bags only | Paper & plastic | Paper & plastic | Paper, E-flute |
| Registration | Precise | ½″ tolerance | ⅛″ tolerance | 1/16″ tolerance | Precise |
Digital Printing
State-of-the-art digital printing produces full-color, photo-quality images directly onto bags. No plates, no screens, no setup fees. Each impression costs just $0.25 per side, plus the cost of the bag. Perfect for small businesses, events, seasonal promotions, and test runs.
Advantages
- Full color — unlimited colors in one pass
- No plate or setup charges
- 1 case minimum (as low as 200–500 bags)
- Near edge-to-edge printing (¼″ border)
- Quick turnaround: 5–7 business days
Available On
- SOS Bags (all sizes)
- Merchandise Bags (all sizes)
- Shipping & Mailer Bags
- Handled Shopping Bags (1 side only)
Flexographic Printing
A rotary printing system using water-based ink and flexible plates mounted on a cylinder. The fastest and most economical post-printing process for paper bags. Best suited for 1–2 color logos on larger production runs.
Advantages
- Most economical for large runs (5,000+)
- 25 standard ink colors + custom PMS matches
- Inline printing = included in bag price on production runs
- Size changes are FREE (combine sizes for quantity pricing)
Limitations
- Paper substrates only (not plastic)
- ½″ registration tolerance
- 45–55 line screen (not for fine detail)
- Heavy coverage not recommended
- Bags with rope handles cannot be flexo printed
Hot Stamping
A metal plate combined with heat, pressure, and duration transfers foil to the bag surface. The only method to achieve a true metallic finish. Available in 50+ foil colors across matte, gloss, metallic, brushed, and special effect finishes. The signature look for premium retail packaging.
Advantages
- True metallic finish (gold, silver, copper, rose gold)
- Works on paper AND plastic bags
- 50+ foil colors including holographic
- 100 bag minimum
- Combine sizes for quantity pricing ($35 plate change fee)
Limitations
- 1 foil color per pass
- ⅛″ registration tolerance
- Cannot handle heavy ink coverage
- Half-tones add texture rather than smooth gradients
- 2nd side adds $150/M + insert charge on some styles
Screen Printing
Ink is pushed through a fine mesh screen to transfer images. The most versatile printing process — gentle, precise, and capable of matching any PMS color on white substrates. UV ink creates a glossy finish; matte or metallic additives available.
Advantages
- Exact PMS color matching
- Up to 3 colors per order
- Tightest registration (1/16″)
- Works on paper AND plastic
- Handles heavy ink coverage
- Glossy, matte, or metallic finish options
- Repeat orders: screen charges waived
Pricing Notes
- Screen charge: $65/screen for new artwork
- PMS ink match: $35/color
- Matte/metallic additive: $20/1,000 impressions
- Ink wash charge ($50) to change colors on press
- Glitter inks: add $40/1,000 impressions
4-Color Process Printing
CMYK process printing separates images into Cyan, Magenta, Yellow, and Black, creating over 16,000 color combinations. Best for photographic images, multi-color logos with tight registration, and printing on textured substrates. No plate charges — pricing includes product, printing, and all setup.
Advantages
- Full spectrum color reproduction
- No plate/screen charges included in price
- No shift tolerance between colors
- Works on textured substrates (E-Flute)
- Short run friendly (50–100 minimum)
Limitations
- More expensive than other methods per unit
- Exact PMS colors not possible (CMYK conversion)
- Must be ordered in full cases
- Excess ink coverage may incur additional charges
Available Foil Colors (Hot Stamp)
Matte Finish
Standard Metallic
Brushed Metallic & Special Effects
Not all foil colors adhere to all product types. Gloss foils do not perform well on natural/uncoated substrates. Contact us for recommendations.
Artwork Requirements
Accepted File Formats
- Preferred: Adobe Illustrator (.ai), EPS, vector PDF
- Accepted: High-res JPEG (300 DPI+) for digital print
- All fonts must be converted to outlines
- Include all linked graphics and source files
Important Notes
- Artwork changes billed at $75/hour ($40 minimum)
- Up to 2 proofs per size included with each order
- Additional proofs: $25–$40 each
- Proof approval required before production begins
- Approvals must be returned within 30 days
Not Sure Which Method Is Right?
Send us your logo and tell us about your project — we’ll recommend the best printing method, substrate, and pricing for your needs.
Request a Custom Quote