In today’s fast-paced and competitive market, packaging is more than just a product container — it is a critical tool for branding, customer engagement, and operational efficiency. Direct-to-package printing is revolutionizing how businesses approach packaging, offering unparalleled flexibility, speed, and customization.
When considering investing in a digital package printing solution, explore these insights into the benefits and key factors of selecting the right system.
The Benefits of Direct-to-Package Printing
- Enhanced Customization
Direct-to-package printing enables businesses to produce high-quality, full-color graphics, variable data, and personalized messages directly onto packaging materials. This capability supports seasonal promotions, limited-edition designs, or targeted campaigns, helping brands stand out and connect with their audience. For example, a branded box supplier created his own niche in real estate segment by offering moving boxes with realtor’s photo, name and contact info. Printed on AstroNova’s AJ-800 printer, these boxes made for a great gift by realtors to their clients for their upcoming move. Similarly, direct-to-package printing can create memorable unboxing experiences by adding customer names or regional-specific designs—a strategy famously employed by a global soft drink manufacturer with their personalized holiday labels. - Streamlined Operations
By investing in a digital short-run printing solution for packaging, printing companies can offer reduced minimum order quantities and lead times to meet requirements of small, independent businesses. This flexibility facilitates on-demand printing, minimizes excess inventory for your customers, and allows for rapid fulfillment.A leading U.S. bakery and delicatessen packaging manufacturer integrated the T3-OPX into their operations to handle custom print jobs without limitations on shapes, sizes, or minimum order quantities. This enabled faster fulfillment and greater adaptability to customer needs. - Cost Savings
Investing in an in-house printer reduces dependency on external vendors, cutting costs associated with outsourcing, storage, and obsolete inventory. Systems with built-in cost calculators, such as the AstroJet AJ-800, provide businesses with tools to analyze and optimize printing expenses. A top-5 commercial printing and print outsourcing solutions provider standardized on AJ-800 to meet short-run printing demands on small boxes, paper bags and mailers from their customer base. The solution allows them to offer same or next-day turnaround times and increase availability of the larger presses for longer run print jobs. - Sustainability and Efficiency
Modern direct-to-package printers, like the AJ-1300, support eco-friendly initiatives through water-based inks and reduced material waste. These features align with growing consumer demand for sustainable practices while maintaining production efficiency.Direct-to-package printing also addresses top megatrends in packaging redesign: sustainability, brand experience, and supply chain agility. A large supplier to independent pizzerias in USA decided to standardize on AJ-1300 to meet rapid fulfillment demand of pizza boxes from their customer base in medium to short-run quantities.
Key Attributes to Consider
When selecting a direct-to-package printing solution, businesses should evaluate these critical attributes:
- Print Technology: Advanced digital technologies, such as water-based inkjet, deliver high-quality results.
- Ink Type: Pigment or dye inks should be chosen based on durability and color vibrancy requirements.
- Print Speed and Resolution: The system should balance speed with sharp image quality.
- Maximum Print Width and Height: The printer must accommodate the dimensions of the packaging being printed.
- Handling and Automation: Features like automatic height calibration, tilt adjustments, and pressure configuration simplify operations and improve accuracy.
- Software Capabilities: Robust print management software ensures seamless integration and operational control.
- Scalability: The printer should handle diverse materials and support productivity improvement options like automatic feeder and/or stacker to support business growth.
Leading Direct-to-Package Solutions
AstroNova offers three industry-leading direct-to-package printers designed to meet diverse business needs:
 TrojanLabel T3-OPX |
 AstroJet AJ-800 |
 AstroJet AJ-1300 |
|
|---|---|---|---|
| Segment | Entry-Level (<$60K) | Value (<$100K) | Production (<$300K) |
| Technology | Water-based Inkjet | Water-based Inkjet | Water-based Inkjet |
| Ink type | CMYK Pigment (230 ml cartridges) |
CMYK Pigment or Dye (5kg Gallon Jugs) |
CMYK Pigment or Dye (5kg Gallon Jugs) |
| Max. Print Resolution | 1200 x 1200 dpi | 1200 x 1200 dpi | 1200 x 1200 dpi |
| Max. Print Width | 11.7” (297 mm) | 17” (432 mm) | 42” (1066 mm) |
| Max. Feed Width | 39.4” (1000 mm) | 31” (787 mm) | 51” (1300 mm) |
| Max. Print Speed | 18 ips (27 m/min) | 18 ips (27 m/min) | 18 ips (27 m/min) |
| Ink Cost | Low | Very Low | Very Low |
| Max. Media Thickness | 95 mm | 203 mm | 50 mm |
| Applications | Postcards, flat corrugated boxes (brown or white), wooden planks, blister envelopes, mailers, paper bags, etc. | Paper bags, flat corrugated boxes (brown or white), mailers, subscription meal boxes, produce boxes, etc. | Flat corrugated boxes or sheets (brown or white) |
| Software/User Interface | TrojanControl UI with Windows Driver, Optional RIP Software | RIP software with Color Management, Color Matching and Hot Folder workflow | RIP software with Color Management, Color Matching and Hot Folder workflow |
Take the Next Step: Direct-to-Package Printing
Direct-to-package printing is the future of packaging solutions. If the goal is greater customization, cost efficiency, or sustainability, direct-to-package printing offers transformative benefits for companies aiming to enhance their packaging strategies.
AstroNova’s AstroJet AJ-1300, AJ-800 and TrojanLabel T3-OPX are cutting-edge direct-to-package printing systems that drive operational success. Learn more, including seeing them in action with virtual online demos here.
