Digital printing has made gains in a wide range of applications, and corrugated is turning out to be promising. HP, EFI, FUJIFILM and Canon are among the leading press and ink manufacturers supplying the market, and converters are finding opportunities for using digital printing for corrugated segments such as signs and displays and boxes.

While digital has made inroads in the market, there is plenty of potential in the overall corrugated market, which is estimated at $250 billion. Digital has a small slice of the market, but if it can overcome challenges and meet the requirements of customers, it could continue to grow rapidly.

Randy Paar, marketing manager – display graphics, large format solutions for Canon Solutions America, pointed out that corrugate is very porous, often warped and as a result very difficult to manage keeping it flat while printing.

“Realizing this challenge, Canon developed a special version of the Arizona 6100 series that implemented a highly powerful blower system that not only sucks down difficult corrugated boards but even ¾ inch warped plywood,” Paar said. “No additional tape is required, which helps the operator be even far more productive compares to a conventional vacuum table.”

Adi Shorer, HP PWI corrugated, product manager, post-print, noted that HP has seen an upswing in online business through e-commerce and web-to-print.

“In addition, small online brands have continued to grow following the COVID crisis, as more people pursue their passions to launch small businesses, whilst more consumers consciously shop local,” added Shorer. “Further emphasis on production flexibility and application versatility is exactly why converters are adopting new digital production technology serving a diverse job basket in the most effective way. HP corrugated presses and workflows are tuned for producing jobs that vary between single to thousands of copies. This provides the flexibility that e-commerce operation requires. What’s more, by using HP PrintOS marketplace, we collaborate with web2print solutions, like boxitnow, providing an integrated platform for selling packages online.”

Evandro Matteucci, VP and GM, packaging and building materials, EFI Inkjet, observed that many factors are involved with adding a new single-pass digital corrugated printer, from manufacturing and shipping to customer site prep and facility construction.

“This became more difficult with the pandemic,” said Matteucci. “But the demand is still there because single-pass digital addresses many converters’ critical needs to drive future profitability and growth.

“To address challenges new customers may face, EFI has focused on being a strong, consultative technology provider for converters making the move to digital corrugated packaging production,” added Matteucci. “Beyond equipment installation, EFI closely collaborates with customers through the necessary technology adoption curve, offering a 12-week ramp-up and training program, a one-year warranty, and 24/7 remote and in-person service maintenance packages.”

Jim Wegemer, director of national accounts for INX International Ink Co., said that digital printing faces a number of challenges while trying to grow its position in corrugated.

“Many people still don’t understand digital printing's strengths and weaknesses,” said Wegemer. “This can lead to graphics that are well suited to flexo or litho but not best suited for digital, and also lead to companies who print digital not understanding how to best sell digital print.

"In the last few years, digital print solutions for corrugated have evolved significantly,” Wegemer added. “Some people considering digital as an option are still looking at what it was capable of two or three years ago, and not what it is truly capable of with the most recent solutions available today. The knowledge that people have of digital solutions and digital capabilities is improving each year. Therefore, digital is improving its foothold and potential in the corrugated market."