Optimizing Inkjet Printing on Cardboard: Challenges, Solutions, and Innovations

Cartons, corrugated boxes, point-of-purchase displays, and signage made from paperboard and cardboard are some of the most widely used packaging materials today. In the U.S. alone, over 80 billion corrugated boxes are produced annually, serving industries from e-commerce and retail to food packaging and logistics.

The widespread appeal of cardboard packaging comes from its lightweight, flexible, and renewable nature. However, while it’s great for protecting products and supporting sustainability goals, it presents unique challenges for high-quality printing. The porous nature of cardboard, ink absorption issues, and color contrast limitations can all impact print clarity, especially for critical elements like barcodes, branding, and tracking codes.

At DPi, we specialize in advanced inkjet printing solutions that address these challenges, delivering sharp, durable prints on cardboard and other packaging materials.

Challenges of Inkjet Printing on Cardboard

Cardboard substrates, whether standard or coated, have distinct properties that impact print quality. Some of the most common printing challenges include:

• Ink Absorption & Blurring – Uncoated cardboard absorbs ink quickly, leading to bleeding and loss of clarity in printed details.

• Unreadable Markings – Poor print contrast can make text, barcodes, and tracking codes difficult to read, creating supply chain issues.

• Scanning Issues – Low-contrast prints on brown or colored cardboard can interfere with barcode readability, disrupting inventory tracking.

• Surface Irregularities – Corrugated cardboard often has a textured or uneven surface, which can impact ink distribution and print consistency.

Fortunately, modern industrial inkjet technology—combined with the right ink formulations—can overcome these issues, providing crisp, legible, and reliable prints.

Types of Cardboard and Their Printing Properties

The surface characteristics of cardboard directly affect how ink interacts with the material. Understanding the differences between coated and uncoated cardboard helps determine the best ink and printing technology for the job.

Uncoated Cardboard

Uncoated cardboard is highly porous, allowing ink to absorb quickly into the fibers. While this can make it difficult to achieve sharp details, it’s a preferred option for certain applications where a natural, matte finish is desired.

Matte Coated Cardboard

Matte coatings offer a smooth surface with reduced ink absorption. This results in better color contrast without excessive glare, making it ideal for packaging that requires a polished look without a glossy finish.

Gloss-Coated Cardboard

Gloss coatings provide a shiny surface that enhances color vibrancy and contrast. This is often used for high-impact branding, retail displays, and promotional packaging where visual appeal is a priority.

Digital Printing Driving Efficiency in the Corrugated Industry

The packaging industry is rapidly adopting high-speed digital inkjet printing to replace traditional flexo and litho processes. Digital printing eliminates the need for expensive plates and lengthy setup times, making it an ideal solution for brands looking for fast, high-quality customization.

The demand for high-resolution graphics on corrugated packaging is growing, especially as retailers shift toward more branded shipping materials and point-of-purchase displays. DPi’s inkjet solutions allow for variable printing at high speeds, supporting brand messaging and compliance requirements without compromising efficiency.

Key Applications of Inkjet Printing on Cardboard

1. Coding and Marking

Inkjet printers are widely used to apply serial numbers, barcodes, batch codes, and expiration dates onto packaging. These markings must be sharp and scannable to maintain supply chain accuracy.

2. Short-Run Custom Packaging

Single-pass inkjet printing is ideal for small-batch, multi-SKU packaging runs. It allows brands to print personalized graphics, limited-edition packaging, and targeted marketing campaigns with ease.

3. Large-Scale Industrial Printing

For mass production, industrial inkjet systems handle high-volume, high-speed printing on sheet-fed or roll-fed corrugated materials, providing consistent, high-quality results.

The Importance of High-Quality Printing on Cardboard

Precision in Marking and Coding

Legible and durable codes are essential for tracking shipments, managing inventory, and meeting retailer requirements. Poorly printed codes can lead to logistical errors, recalls, and regulatory compliance issues.

Branding and Customer Experience

With e-commerce and direct-to-consumer shipping on the rise, packaging plays a significant role in brand perception. Unique and high-quality prints enhance the unboxing experience, helping companies differentiate their products.

Innovative Visual Effects with Inkjet Printing

Advancements in inkjet technology allow brands to incorporate visually striking and tactile effects on their packaging, including:

• Embossing Effects – UV-curable ink can be layered to create raised textures for a premium look and feel.

• Condensation Effects – Raised ink applications can mimic water droplets, enhancing beverage and cosmetics packaging.

• Textured Leather Finishes – High-end brands can replicate the appearance of leather or fabric, elevating their packaging design.

• Invisible and Heat-Activated Inks – Thermochromic and security inks create interactive packaging experiences, adding an element of surprise for consumers.

Sustainability and Cost Savings with Inkjet Printing

Eco-conscious packaging is becoming a priority across industries. Inkjet technology supports sustainable initiatives by:

• Reducing Waste – Digital printing eliminates excess materials used in traditional printing methods, cutting down on production waste.

• Lowering Energy Consumption – Inkjet systems require fewer resources and generate less waste compared to flexographic and lithographic printing.

• Using Eco-Friendly Inks – Water-based, solvent-free, and bio-renewable inks reduce environmental impact while delivering high-performance results.

By integrating inkjet printing into their operations, brands can improve efficiency, reduce costs, and meet evolving sustainability goals.

The Advantages of Inkjet Printing for Cardboard Packaging

• Variable Data and Personalization – Print unique barcodes, tracking codes, and promotional messages without slowing production.

• Multi-SKU Flexibility – Digital inkjet technology supports mixed production runs, making it ideal for brands with diverse packaging needs.

• Non-Contact Printing – Unlike flexo printing, inkjet technology doesn’t require direct contact with the substrate, preventing damage to delicate materials.

The Right Inkjet Technology for Your Needs

DPi provides advanced inkjet solutions for printing on all types of cardboard substrates, whether for branding, compliance, or logistics. Our expertise in inkjet printing ensures optimal performance, whether using thermal, piezo, or continuous inkjet technologies.

If you need guidance on selecting the right ink and technology for your application, contact our team today to find the best solution for your packaging needs.