Carton Bosrd and Paper
The uncomfortable truth about traditional carton production
By Lachlan Buirds, managing director, Edale
F
olding carton production has been traditionally dominated by a familiar pattern: sheet-fed litho, multiple offl ine processes and complex production
chains built for scale.
That model worked when runs were long, SKUs were stable and speed was less critical. Today, those conditions no longer apply.
Shorter runs, faster turnaround expectations, labour constraints and sustainability pressure are forcing converters to question whether traditional carton workfl ows are still fi t for purpose. In the UK and wider European market, folding cartons continue to grow strongly, with the global carton sector forecast to expand at around 5.8 per cent CAGR through to 2034. Growth alone, however, does not tell the full story. What is reshaping carton production is not volume, but variability.
Shorter runs, rising SKU counts, faster turnaround expectations and increased embellishment requirements are becoming the norm. At the same time, converters face persistent labour shortages, rising energy costs and pressure to reduce waste and work in progress. In this environment, legacy production habits are being questioned more openly than before.
FROM SCALE EFFICIENCY TO WORKFLOW EFFICIENCY
Traditional litho workfl ows are optimised for scale. But scale is no longer the dominant challenge facing carton converters. As runs fragment and SKU counts rise, the cost of complexity becomes impossible to ignore.
Every additional process step adds time, labour, risk and work in progress. In this environment, workfl ow effi ciency matters more than legacy process loyalty.
This is where fl exographic production is attracting renewed attention, as either a replacement for litho, or as a complementary and sometimes leading route. FLEXO QUALITY IS NO LONGER THE LIMITING FACTOR
Image quality is no longer the limiting factor in carton fl exo. Advances in plate technology, automation and register control mean fl exo now meets brand expectations across a wide range of carton applications. For many converters, quality is no longer the question. Workfl ow effi ciency is. More importantly, fl exo off ers consistency. Stable registration and repeatability across runs reduce the need for constant operator intervention and extended makeready. For many converters, the quality debate has shifted from “can fl exo match litho?” to “can we maintain quality while reducing complexity?”
SINGLE-PASS THINKING CHANGES THE COMMERCIAL EQUATION The real diff erentiator is not fl exo as a print process, but fl exo-led, single-pass workfl ows. By bringing printing, embellishment and converting together into one controlled process, converters can dramatically reduce handling, work in progress and fl oor space.
Industry analysis suggests that on mid-run carton work, fl exo-based production can deliver signifi cant advantages in makeready time and total project cost compared to traditional litho routes. Smithers notes that fl exo’s strength lies in faster setup and lower cost for repeatable work, particularly as automation continues to reduce manual intervention. When viewed through a workfl ow lens, the comparison is no longer off set versus fl exo, but multi-stage versus consolidated production.
A PRAGMATIC SHIFT, NOT A WHOLESALE REPLACEMENT
None of this suggests that litho is disappearing from carton board production. Sheet-fed off set
remains highly eff ective for certain applications, particularly where very high sheet counts, complex structural designs or specifi c fi nishing requirements dominate. What is changing is how converters deploy diff erent technologies. Flexo is increasingly being used where agility, turnaround and workfl ow effi ciency matter most, while litho retains its role where scale and sheet versatility are critical. The most successful operations are those that understand the strengths and limitations of each process and deploy them strategically. This pragmatic approach is particularly relevant in the UK market, where many converters operate mid-sized plants and need to balance growth with operational control.
DESIGNING TODAY’S CARTON WORKFLOWS The move towards fl exo-led carton production also places greater emphasis on design for manufacture. Artwork, substrates and embellishment choices must be aligned with inline production principles. When that alignment is achieved, the benefi ts compound: faster changeovers, reduced waste and more predictable scheduling.
Converters who have made the transition consistently report that the biggest gains are not just in throughput, but in planning confi dence. With fewer variables and handoff s, production becomes easier to manage and scale.
THE NEXT PHASE OF CARTON GROWTH As carton board and paper packaging continue to expand, driven by sustainability initiatives and brand preferences, production effi ciency will become an even greater diff erentiator. Flexo is not re-emerging because it is new, but because it aligns well with the realities of modern carton production.
Carton production is not being redefi ned by technology alone, but by the need to do more with fewer steps, fewer people and less waste. For converters willing to challenge established
workfl ows, fl exo-led production is no longer an alternative route. It is becoming a strategic one.
16
February 2026
www.convertermag.com
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