Why flexo is ready for short run carton production
Short-run carton work has always been a balancing act. Brands want premium quality, quick turnaround, and competitive pricing.
But for years, traditional offset workflows have struggled to make short runs profitable. Long setup times, multiple process stages, and high waste rates all erode margins when run lengths drop.
Modern flexographic technology is changing that equation as platforms like Edale’s CartonLine are optimised for this shift, giving converters the speed, quality, and flexibility to make short-run cartons highly profitable.
From long-run specialist to short-run champion
Flexo’s reputation was built on high-volume output, ideal for labels and corrugated, less so for premium cartons. But over the last decade, HD flexo plates, precision servo control, and advanced drying systems have transformed what’s possible.
Today’s single-pass flexo presses, such as the Edale CartonLine, deliver offset-quality print in runs of just a few hundred sheets, with less waste, faster setup, and inline finishing.
Why short-run demand is exploding
The surge in short-run carton production isn’t a passing phase, it’s a structural shift in the market, driven by three powerful forces.
The first is SKU proliferation, as brands are producing more variations of the same product than ever before, driven by seasonal promotions, regional regulations, influencer collaborations, and even personalisation campaigns. A single product line might have dozens of versions, each requiring high-quality, low-volume packaging.
Second is faster product cycles, due to the simple fact that e-commerce and direct-to-consumer (D2C) models now thrive on speed. Products launch faster, stay on the market for shorter periods, and are constantly updated. That puts pressure on converters to deliver premium cartons in days, not weeks.
Finally, sustainability and efficiency pressures are just growing and growing. Overproduction isn’t just costly; it’s damaging to both margins and brand image. Short runs help match supply with demand, reducing waste and aligning with corporate ESG commitments.
Flexo’s advantages in the short-run space
This is where modern flexo, and platforms like Edale’s CartonLine, really shine.
- Faster makereadies – Automation is the game-changer. Systems like Edale’s AiiR handle registration, impression, and inking with pinpoint accuracy, slashing changeover times and enabling converters to run multiple jobs in a single shift without compromise.
- Lower waste – Short runs often use premium or sustainable substrates, which means every sheet counts. Precision setup ensures minimal material loss, protecting both profit margins and sustainability goals.
- Inline finishing – High-value embellishments like foil, cast & cure, embossing, and die-cutting are handled in a single pass. This not only saves time but removes the need for secondary processes, outsourcing, or extra transport, reducing lead times and carbon footprint.
- Scalable capacity – With a modular press like the CartonLine, converters can start with a lean, cost-efficient configuration for short runs, then add print or embellishment units as demand grows. It’s a future-proof investment that scales with the business.
Quality without compromise
The old assumption that short runs demand digital or hybrid is fading fast. Modern flexo delivers the colour accuracy, fine detail, and premium finishes that brand owners expect, often at a lower cost per unit than digital for mid-length runs.
Short runs aren’t a niche trend; they’re a central part of the folding carton future. Investing in a single-pass flexo platform like the Edale CartonLine not only opens new short-run revenue streams but gives you the flexibility to handle long runs just as efficiently.
With the CartonLine, converters don’t need separate equipment for long and short runs. The same line can deliver a few hundred high-value cartons or a high-volume production run without compromise.
For converters ready to expand their offer, flexo is no longer the “maybe later” option. It’s the ready now solution. It is fast, flexible, and built for the demands of today’s packaging market.
Want to see the difference for yourself?
If you’ve been told that flexo can’t deliver the print quality your customers expect, we’d love to show you otherwise.
The Edale CartonLine is helping carton converters across the globe produce premium packaging with speed, efficiency and consistency and a price point that will make you smile!
Get in touch with the Edale team to discuss how flexo can transform your carton production, and why now is the time to make the switch.