Key takeaways

• We print non-woven bags by screen, flexographic, rotogravure and offset printing.
• Screen printing suits bold, solid logos and smaller runs; flexo suits crisp logos at volume.
• Rotogravure under lamination gives photographic, full-colour designs protected from scratches and moisture.
• Set-up costs make some methods better for small runs and others for large runs and repeats.
• Supply vector artwork, Pantone references and clear margins, and always check the proof.

Introduction

The printing on a bag is what turns it from a useful carrier into a piece of marketing. A crisp logo, a bold colour and a clear message make a bag recognisable from across the street. A blurred logo, faded colour or misprinted phone number does the opposite.

Non-woven bags can be printed in several ways, and each method has its own look, colour range, cost structure and ideal order size. Choosing the right method depends on your artwork, your budget, the number of bags and the impression you want to make.

We print non-woven bags using four methods: screen, flexographic, rotogravure and offset. This article explains how each works, what it is best for, how it affects cost, how to prepare artwork for it and how to judge print quality. It also briefly covers heat transfer and digital printing, which some suppliers offer. It ends with an illustrative example and answers to common questions.

Why printing method matters

The printing method affects:

• How the design looks: solid colours, fine detail, gradients or photographs;
• How many colours can be printed: from a single colour to full colour;
• Set-up cost: screens, plates or cylinders must be made before printing;
• Cost per bag: which falls as quantities rise, at different rates for each method;
• Durability: how well the print resists rubbing, folding and moisture; and
• Lead time: how long tooling and printing take.

Screen printing

How it works

Screen printing pushes ink through a fine mesh screen onto the fabric. A stencil on the screen blocks the mesh everywhere except the design, so ink passes through only where it is needed. Each colour needs its own screen, and colours are printed one after another.

We screen print with water-based inks on a roll-to-roll automatic screen printing machine, which prints continuous fabric before it is formed into bags. This gives consistent results across large quantities.

Strengths

• Bold, solid, opaque colours that stand out on coloured fabric;
• Low set-up cost, because screens are relatively simple to make;
• Well suited to logos, shop names and contact details; and
• Economical for small to medium quantities.

Limitations

• Usually limited to one to a few colours;
• Not suited to photographs or smooth gradients; and
• Very fine detail can be lost on the fabric’s textured surface.

Best for

Shop logos, event bags, promotional giveaways and any design with a few solid colours. Our screen printed bags use 60, 80 or 120 GSM fabric.

Flexographic printing

How it works

Flexographic (flexo) printing uses flexible photopolymer plates with raised image areas. Ink is transferred to the plates by an engraved roller called an anilox roller, and the plates print onto the fabric or film as it runs through the press at high speed. Each colour has its own plate and printing station.

Strengths

• Fast, efficient printing for medium and long runs;
• Crisp logos and text;
• Plates are cheaper and quicker to make than gravure cylinders; and
• Works with water-based inks.

Limitations

• Less suited to very fine photographic detail than rotogravure;
• Usually a limited number of colours; and
• Plate costs make very short runs less economical.

Best for

D-cut, W-cut, loop handle and box bags with logos and text in a few colours, in medium to large quantities. Flexo printing is also used for metallic and shimmer bags.

Rotogravure printing

How it works

Rotogravure printing uses metal cylinders engraved with millions of tiny cells. Each cylinder carries one colour. As the cylinder turns through an ink bath, the cells fill with ink, a blade wipes the surface clean, and the ink in the cells transfers to the film. Deeper cells carry more ink and print darker tones, which allows smooth gradients and photographic images.

For non-woven bags, rotogravure is usually used to reverse print a clear film, which is then laminated to the non-woven fabric. The ink ends up sealed between the film and the fabric, protected from scratches and moisture.

Strengths

• Photographic, full-colour images with smooth gradients;
• Rich, vivid, consistent colour across very long runs;
• Print protected under lamination; and
• Premium appearance for promotional and retail bags.

Limitations

• Highest set-up cost, because each colour needs an engraved cylinder;
• Longer lead time for first orders; and
• Best value only for larger quantities, though cylinders can be stored for repeat orders.

Best for

Laminated promotional box bags, PP woven box bags, D-cut and loop handle bags with full-colour designs, and any bag where a photograph or complex artwork must look its best.

Offset printing

How it works

Offset printing transfers ink from a metal plate to a rubber blanket, and from the blanket to the material being printed. It produces sharp, detailed, full-colour images.

Best for

We use offset printing for non-woven packaging bags, such as rice and grain bags, where detailed product artwork, pack information and branding must look sharp on the shelf. Our packaging bags use 130 GSM fabric with industrial sewing.

Other methods: heat transfer and digital

Some suppliers also offer:

• Heat transfer printing, where a design printed on transfer film is applied to the bag with heat and pressure. It can reproduce detailed, multi-colour designs on small quantities, but can be slower and more expensive per bag.
• Digital printing, which prints directly from a digital file without plates or screens. It suits very small runs and samples, but cost per bag is usually higher for large quantities.

Ask us if you need very small quantities or samples, and we will advise on the most practical option.

Comparing the methods

How printing affects cost

Every printing method has two kinds of cost:

• Set-up costs, such as screens, plates or engraved cylinders, and the time to set up the press. These are paid once per design.
• Running costs, such as ink, press time and labour, which are paid for every bag.

For small orders, set-up costs make up a large share of the price per bag, so methods with low set-up costs, such as screen printing, are often best. For large orders, set-up costs are spread over many bags, so methods with high set-up costs but low running costs, such as rotogravure, become economical. Repeat orders that reuse stored tooling are more economical still.

Ways to reduce printing costs:

• use fewer colours;
• keep the same artwork across sizes and reorders;
• choose a printing method that matches your order size; and
• order larger quantities less often.

Preparing artwork for printing

Our design team can prepare or adapt artwork for the chosen printing method, and we send a proof before production.

Printing on coloured fabric

Plain non-woven bags come in many fabric colours, and the fabric colour affects how printed inks look:

• Dark inks on light fabric (for example navy on white) give the clearest result and are easy to print.
• Light inks on dark fabric (for example white or yellow on black or navy) need opaque inks, and sometimes a white base layer, to look bright.
• Similar colours (for example red on orange) give poor contrast and are hard to read.

Screen printing is especially good on coloured fabric because its thick, opaque ink layers stand out. For laminated bags, the film carries the colour, so fabric colour matters much less.

Design tips for each method

Screen printing

• Keep designs bold and simple, with solid shapes and clear text.
• Avoid very thin lines and very small text, which can fill in on the fabric texture.
• Limit the number of colours to control cost.

Flexographic printing

• Logos and text print crisply; keep fine detail to a sensible size.
• Use solid colours and simple tints rather than photographs.
• Allow for slight variation in very fine registration between colours.

Rotogravure printing

• Use high-resolution images and full-bleed backgrounds if you wish; rotogravure handles them well.
• Use rich colours and photography to make the most of the method.
• Keep important text away from seams and gussets.

Offset printing on packaging bags

• Include all required pack information, such as product name, net weight and other details required by regulation, in a clear layout.
• Use high-resolution product photography for shelf appeal.

Printing on both sides and on gussets

Most bags can be printed on the front and the back. Box bags can also be printed on the gussets, which is useful for a website address, social media handles or a simple pattern. With rotogravure printing on laminated bags, the whole outer surface can be covered with a continuous design. Printing more areas and colours adds cost, so focus on the faces customers see most.

Common printing problems and how to avoid them

Judging print quality

When your bags arrive, or when you check a sample, look for:

• Sharp edges on logos and text;
• Accurate colours compared with your brand colours and the approved proof;
• Good registration, with colours lined up exactly;
• Even coverage, without streaks, patches or missing ink;
• Correct position of the design on each bag; and
• Durability, with no ink rubbing off when you fold or rub the print.

Print durability and care

Print durability depends on the method and finish:

• Rotogravure under lamination is the most protected, because the ink sits beneath the film.
• Screen and flexo prints on plain non-woven fabric are durable for normal use but can wear with heavy rubbing or harsh washing.
• Offset printing on packaging bags is designed to look sharp on the shelf and through the product’s use.

To keep prints looking good, customers should wipe laminated bags clean, hand-wash plain non-woven bags gently in cool water and avoid ironing printed areas.

Matching method to bag type

Choosing a method: a quick decision guide

Answer these questions to narrow down the right printing method:

1. Does your design include a photograph or complex full-colour artwork? If yes, choose rotogravure on a laminated bag.
2. Is it a logo or text in one to a few solid colours? If yes, choose screen or flexo printing.
3. How many bags do you need? For smaller quantities, screen printing is often the most economical; for larger quantities, flexo and rotogravure become better value.
4. Is it a packaging bag for a product such as rice? Offset printing gives sharp, detailed pack artwork.
5. Do you need a premium, protected finish? Rotogravure under lamination keeps the print safe from scratches and moisture.
6. Will you reorder the same design? If so, investing in rotogravure cylinders or flexo plates pays back over repeat orders.

If you are still unsure, send us your artwork and quantity, and we will recommend the method that gives the best result for your budget.

An example in practice

The following example is illustrative and does not describe a real customer.

A sports shop wants 3,000 bags with its two-colour logo for everyday use, and 10,000 premium bags with a full-colour photograph of athletes for a new store opening. For the everyday bags, we recommend flexo printing on 80 GSM loop handle bags: two plates, crisp logo, economical at that quantity. For the opening campaign, we recommend rotogravure printing on laminated box bags, which reproduce the photograph vividly and protect it under the film.

Both designs are proofed and approved. Months later, the shop reorders the premium bags for its second branch, and because the cylinders are stored, the repeat order is quicker and more economical.

Frequently asked questions

Which printing method gives the best quality?

For photographs and full-colour designs, rotogravure printing on laminated bags gives the richest, most detailed result. For simple logos, screen and flexo printing look crisp and bold.

Which method is cheapest?

It depends on quantity. Screen printing is often most economical for small runs; flexo and rotogravure become more economical as quantities increase.

Can you print photographs on non-woven bags?

Yes. Photographs are best printed by rotogravure on a film that is laminated to the bag.

Do you use water-based inks?

Our screen printing uses water-based inks on a roll-to-roll automatic screen printing machine. Flexo printing can also use water-based inks.

Why does the first order cost more?

First orders include set-up costs such as screens, plates or cylinders. These can be reused for repeat orders.

Can you match our brand colours?

Yes. Provide Pantone references, and we match inks to your brand colours and confirm them on the proof.

Can I print different designs on the same bag type?

Yes. Each design needs its own screens, plates or cylinders, but you can order several designs in the same bag type and size, for example for different branches or seasons.

How many colours can rotogravure print?

Rotogravure can reproduce full-colour photographs using process colours, and extra spot colours can be added for exact brand colours, each with its own cylinder.

Will the print fade in the sun?

Prints protected under lamination resist fading and scuffing best. Any printed bag will fade gradually if left in strong sunlight for long periods, so store bags out of direct sun.

Conclusion

Screen printing gives bold, solid colours at low set-up cost; flexo printing delivers crisp logos efficiently at volume; rotogravure produces photographic, full-colour designs protected under lamination; and offset printing gives sharp detail on packaging bags. The right choice depends on your artwork, quantity, budget and the impression you want to make.

Not sure which printing method suits your bag? Ask our team for advice and a proof.

Get Printing Advice

Related reading

• How Non-Woven Bags Are Made: From Polypropylene to a Printed, Branded Bag
• Designing a Custom Printed Non-Woven Bag: Size, Strength, Artwork and Ordering
• Non-Woven Bag Types Guide: D-Cut, Loop Handle, W-Cut, Box, Stitched, Laminated, Metallic, Packaging and Thermal Bags
• How to Choose the Right GSM for Non-Woven Bags
• Non-Woven, Paper or Plastic: Which Bag Wins?
• See all non-woven bags

Sources

• Product specifications from the owner's bag catalogue (printing methods for each bag type)
• CXGIAE, PP non-woven bags: a complete guide for wholesale buyers (printing methods): https://cxgiae.com/blog/pp-non-woven-bags-a-complete-guide-for-wholesale-buyers/
• BK Bags, PP non-woven bags (lamination and print methods): https://bk-bags.com/shop/pp-non-woven/
• THE RPS LLC, non-woven bag printing supplier (printing methods and artwork requirements): https://therpsllc.com/product/non-woven-bag-printing-supplier-dubai/
• Flexographic Technical Association, about flexography: https://www.flexography.org/