Plan Ahead with Digital Printing: How Packaging Converters Can Win Short-Run, Multi-SKU Orders

A Canadian packaging converter recently won a brand packaging order with three key requirements: a short run, fast delivery, and four SKUs.

This type of order is becoming increasingly common for packaging converters.

For color box and carton converters, producing these jobs at a viable cost means taking on business that may have been difficult to make profitable with conventional production. Those unable to handle short runs and multiple SKUs risk missing these opportunities.

For converters that rely heavily on offset printing, short-run, multi-SKU jobs often come with higher plate and makeready costs. When four SKUs require four separate plate sets, fixed setup costs have a greater impact on margins as order volumes decrease.

This is where digital printing is gaining ground.

Digital Printing Is Improving Packaging Productivity

Digital printing still represents a relatively small share of the global packaging market, but demand for short-run packaging continues to grow.

According to the latest Smithers research, the global digital packaging and labels market was worth approximately $22 billion in 2025. Digital printing accounted for 1.3% of packaging print volume and 4.1% by value. The market is forecast to reach approximately $36.9 billion by 2030.

Digital printing is not yet the dominant production method for packaging, but adoption is growing in short runs, fast turnaround, multiple versions, and highly flexible production. Smithers expects digital printing to gain further ground across cartons, corrugated packaging, and flexible packaging.

The opportunity is therefore not simply about replacing conventional printing. It is also about efficiently handling jobs that are difficult to produce economically with traditional processes.

Short runs, tight deadlines, multiple SKUs, and frequent version changes are becoming key applications for digital packaging print.

Speed Matters. Flexibility Creates the Value.

Speed matters, but converters investing in digital printing are not simply buying more square meters per hour.

The real advantage is the ability to combine production speed with job flexibility.

Baosiwei's 24-head digital printer for color box packaging eliminates traditional plate making and complex prepress setup, allowing converters to switch between jobs more efficiently.

A converter can run 500 pieces for a new product launch, switch to 2,000 pieces for a seasonal campaign, then produce additional quantities as demand develops. New packaging versions can also be produced quickly when regulatory or product information changes.

For these jobs, digital printing reduces makeready time and makes it easier to schedule different quantities and SKUs on the same production line.

Substrate flexibility is another important factor. Depending on the model and configuration, Baosiwei's digital packaging printing solutions support 80–400 g/m² paper, including white card stock, grey-back white paper, and coated paper.

For converters producing color boxes, cartons, and other paper-based packaging, a flexible digital production system can bring more short-run work into the same workflow.

Automation Makes Short-Run Production More Efficient

Another challenge for packaging converters is the growing need to reduce reliance on highly experienced operators.

Traditional printing requires substantial operator expertise in color calibration, registration, and prepress preparation.

A standardized digital workflow can reduce dependence on individual operator experience.

Baosiwei's 24-head digital printer can integrate with RIP and color management software for file processing, color separation, screening, ICC color management, imposition, variable data, and machine control. This helps standardize file preparation and production parameters.

Automation can also extend beyond the printing stage.

Baosiwei's integrated system combines printing, registration correction, lamination, and cutting in one workflow.

For short-run, multi-SKU, rush, and small-volume jobs, this can reduce roll handling, reloading, manual alignment, and intermediate material transfer.

With the appropriate configuration, the complete line can be operated by one operator, reducing manual handling while also minimizing work-in-process and floor-space requirements.

Printing, lamination, and cutting can then run as a more continuous process.

Digital printing is therefore no longer just a printing step. It can become a complete short-run packaging production line.

Long Runs Remain a Strength of Conventional Printing

Digital printing is not about replacing offset printing.

For converters focused on stable designs, single-SKU production, and very large volumes, offset still offers strong economies of scale.

The practical approach is a hybrid production model.

Offset continues to handle high-volume, stable, long-run jobs. Digital printing takes on short runs, multiple SKUs, fast-turnaround work, frequent version changes, and quick replenishment.

The two technologies are not mutually exclusive. They can serve different jobs within the same production operation.

For packaging converters, the value of digital printing is not having to replace existing equipment. It is having another production option for jobs that were previously difficult to quote or make profitable.

Short-run work that once went to another converter can stay in-house. Replenishment orders that previously required longer lead times can be turned around faster.

Digital capacity can therefore become more than a production technology. It can help converters win new customers and expand the range of work they can profitably take on.

Plan Ahead Instead of Waiting for the Orders

Digital printing is not gaining ground because it will replace every conventional printing process.

Its growth is being driven in part by the increasing demand for short runs, multiple versions, and fast turnaround.

The packaging industry is seeing the same shift.

The question for converters is not simply:

“When will digital printing replace offset?”

It is:

“When a customer comes with four SKUs, a few thousand pieces, and a tight deadline, do we have a cost-effective way to produce the job?”

If the answer is no, digital capacity may no longer be just a future investment. It may need to be part of today's capacity planning.

Baosiwei's 24-head digital printer for color box packaging is designed around this shift.

By integrating digital printing, registration correction, lamination, and cutting, it helps converters maintain their existing long-run capabilities while adding digital production capacity for short-run, multi-SKU, and fast-turnaround orders.

Building this flexibility in advance is not about replacing existing production methods. It is about having more options as the order mix changes.

Fast-turnaround orders are growing. The competitive question is shifting from “Can we produce it?” to “Can we produce it efficiently, consistently, and profitably?”

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