The short answer: digital for short runs, offset for volume. The longer answer is that each method has specific strengths, and some jobs are best done with a combination of the two.
Digital strengths
- No plate costs — economical from 50 labels up
- Variable data — each label in a run can carry different artwork, batch, serial
- Fast turnaround — no plate-making step, 7-10 day standard
- Lower setup waste — little makeready material
- Easy proof-to-production — what you proof is what you print
Offset strengths
- Lowest per-unit cost at volume — scales beautifully above 10,000 labels
- Specialty inks — metallics, fluorescents, extended-gamut, opaque whites
- Rock-solid colour consistency — across huge runs over multiple years
- High-speed production — long runs finish quickly once set up
- Plate reuse — repeat orders are fast and cheap
The cost crossover
Rough rule of thumb, for standard 4-colour artwork on BOPP:
- Under 2,000 labels: digital is clearly cheaper
- 2,000-10,000: it depends on finishing and material — often close
- 10,000-20,000: roughly break-even, lean toward offset if repeat order
- Over 20,000: offset is clearly cheaper
The real question isn’t “which method”
It’s which method for which run. A brand launching 500 labels of a new SKU should print digitally. The same brand, two years later, pushing 50,000 labels every quarter? Move it to offset. The transition happens when your repeat volume justifies amortising plate costs across it.