Printing on Corrugated Plastic: A Comprehensive Guide

Printing on corrugated plastic has become increasingly popular due to its versatility and durability. Whether you’re looking to create signage, packaging, or promotional materials, understanding the process and best practices is essential for achieving high-quality results. In this comprehensive guide, we will explore the ins and outs of printing on corrugated plastic, covering everything from the materials and equipment needed to the techniques and design considerations.

Understanding Corrugated Plastic

Composition and Properties

Corrugated plastic, also known as coroplast, is a lightweight and durable material made from twin-wall polypropylene sheets. These sheets have a series of parallel ridges and alternating grooves, providing strength and stability. The fluted design not only enhances the material’s rigidity but also allows for better print adhesion.

Corrugated plastic offers several advantages over traditional materials like cardboard or paper. It is water-resistant, weatherproof, and resistant to UV rays, making it ideal for both indoor and outdoor applications. Additionally, it is easy to cut, fold, and manipulate, allowing for various creative possibilities.

Applications of Corrugated Plastic

Corrugated plastic finds applications in a wide range of industries. It is commonly used for signage, such as yard signs, real estate signs, and event banners, due to its weather resistance and durability. The material’s versatility extends to packaging, where it can be used for boxes, dividers, and protective padding. Corrugated plastic is also popular in industries like construction, agriculture, and advertising, where its lightweight nature and strength make it an ideal choice.

Preparing the Artwork

Resolution and File Formats

When preparing the artwork for printing on corrugated plastic, it is crucial to consider the resolution and file format. For optimal results, use high-resolution images with a minimum of 300 dots per inch (DPI). This ensures that the prints are sharp and clear, even when viewed up close. Additionally, save your artwork in a vector format like Adobe Illustrator (.ai) or EPS (.eps) to maintain image quality and scalability.

Color Mode and Color Profiles

Choosing the right color mode is essential to accurately reproduce colors in your prints. RGB color mode is commonly used for digital artwork and is suitable for designs intended for display on screens. However, for print purposes, it is crucial to convert your artwork to CMYK color mode. CMYK represents the four ink colors used in the printing process: Cyan, Magenta, Yellow, and Black. Converting to CMYK ensures that the colors in your design are accurately translated onto the corrugated plastic.

Design Considerations

When designing artwork for corrugated plastic printing, keep in mind the material’s unique properties and limitations. The fluted surface of corrugated plastic may affect the sharpness of fine details, especially if they are too small or intricate. Consider using bold and simple designs that can withstand the texture of the material. Additionally, ensure that important elements, such as text or logos, are placed within the printable area and not too close to the edges, as they may be compromised during the cutting or folding process.

Choosing the Right Printing Method

Screen Printing

Screen printing is a popular method for printing on corrugated plastic, especially for large quantities and simple designs. It involves pushing ink through a mesh screen onto the material, creating vibrant and long-lasting prints. Screen printing is known for its excellent color opacity and durability, making it suitable for outdoor applications. However, it may not be cost-effective for small print runs or complex designs due to the setup and screen preparation involved.

Digital Printing

Digital printing has gained popularity in recent years due to its versatility and cost-efficiency, particularly for short print runs and intricate designs. This method utilizes inkjet or laser printers that directly apply ink onto the corrugated plastic. Digital printing offers the advantage of quick turnaround times, variable data printing capabilities, and the ability to reproduce detailed artwork accurately. However, it may not provide the same level of color opacity and longevity as screen printing for outdoor applications.


Flexography, commonly used for packaging printing, is another viable option for printing on corrugated plastic. It involves using flexible rubber or polymer plates mounted on cylinders to transfer ink onto the material. Flexography offers excellent print quality, high-speed production, and the capability to print on various substrates. While it may require specialized equipment and setup, flexography is well-suited for large print runs and delivers consistent and vibrant results.

Selecting Inks and Substrates

Inks for Corrugated Plastic

Choosing the right ink is crucial for achieving optimal print quality and longevity on corrugated plastic. Solvent-based inks are commonly used due to their excellent adhesion, durability, and resistance to fading. They penetrate the material’s surface, ensuring long-lasting prints that can withstand exposure to harsh weather conditions. UV-curable inks, which cure instantly under ultraviolet light, are also suitable for corrugated plastic printing, offering vibrant colors and environmental benefits.

Substrates for Corrugated Plastic

Corrugated plastic itself serves as the substrate for printing, providing a sturdy and stable surface for the ink. However, additional substrates may be used for specific applications or to enhance the print quality further. For example, applying a primer or coating on the corrugated plastic can improve ink adhesion and prevent smudging. Laminating the prints with a clear protective film can enhance their durability, resistance to scratching, and fading, making them suitable for long-term outdoor use.

Preparing the Corrugated Plastic Sheets

Cleaning and Pre-Treatment

Prior to printing, it is essential to ensure that the corrugated plastic sheets are clean and free from any contaminants that may interfere with ink adhesion. Use a mild detergent or cleaning solution to remove dirt, grease, or dust particles from the surface. Rinse the sheets thoroughly and allow them to dry completely before proceeding to the next step.

Priming and Coating

Applying a primer or coating on the corrugated plastic can enhance ink adhesion and improve print quality. Primers create a smooth and uniform surface, ensuring that the ink spreads evenly and adheres well to the material. Coatings, on the other hand, provide an additional layer of protection and can enhance the vibrancy and longevity of the prints. It is important to choose primers and coatings specifically designed for use with corrugated plastic.

Masking and Registration

If your design requires multiple colors or layers, it is crucial to mask and register the corrugated plastic sheets accurately. Masking involves covering specific areas of the sheet to prevent ink from being applied, while registration ensures proper alignment of the printed layers. Using masking tapes or registration marks can help achieve precise and consistent results, especially when working with complex designs or intricate patterns.

Setting Up the Printing Equipment

Choosing the Right Printer

When printing on corrugated plastic, selecting the appropriate printer is essential for achieving high-quality results. For screen printing, choose a press that can accommodate the desired print size and offers the necessary registration and color control features. Digital printers should have the capability to handle corrugated plastic sheets of the desired thickness and provide adequate ink coverage and resolution. Ensure that the printer’s specifications align with your specific requirements to ensure optimal performance.

Calibration and Color Management

Calibrating the printing equipment is crucial for accurate color reproduction on corrugated plastic. This involves adjusting the printer settings, such as ink density, dot gain, and color profiles, to match the desired output. Color management systems and software can aid in maintaining consistency across multiple prints and different printing devices. Regular calibration and color profiling ensure that the prints meet the desired color accuracy and consistency, enhancing the overall quality of the final product.

Ink Drying and Curing

Proper ink drying or curing is essential to prevent smudging or smearing of the prints. Solvent-based inks typically require sufficient drying time to allow the solvents to evaporate fully. UV-curable inks, on the other hand, cure instantly under ultraviolet light, eliminating the need for prolonged drying periods. Ensure that the printing equipment is properly set up to facilitate adequate drying or curing, as insufficient drying time can compromise the print quality and adhesion to the corrugated plastic.

Printing Techniques and Tips

Color Mixing and Pantone Matching

If your design requires specific colors or Pantone matching, it is essential to have a thorough understanding of color mixing and ink preparation. Follow the manufacturer’s guidelines for color mixing ratios and ensure that the inks are thoroughly mixed to achieve consistent and accurate colors. Test prints and color swatches can help verify color accuracy and match Pantone references, ensuring that the final prints meet your expectations.

Print Registration and Alignment

Print registration is crucial when working with designs that require multiple colors or layers. Proper alignment of the printed layers ensures that the final print appears cohesive and accurate. Utilize registration marks or guides to achieve precise alignment and maintain consistency acrossmultiple prints. Regularly check and adjust the registration settings to ensure that each color or layer lines up correctly. It may be necessary to make slight adjustments during the printing process to achieve the desired alignment.

Ink Adhesion and Coverage

To ensure optimal adhesion of the ink to the corrugated plastic, it is important to achieve proper ink coverage. Insufficient ink coverage may result in a faded or patchy appearance, while excessive ink can lead to smudging or smearing. Adjust the ink density and print settings to achieve consistent and even ink coverage across the entire print. Conduct regular quality checks throughout the printing process to ensure that the ink adheres well to the corrugated plastic and produces vibrant and long-lasting prints.

Color Consistency and Calibration

Consistency in color reproduction is crucial when printing on corrugated plastic, especially for projects that require multiple prints or repeat orders. Regularly calibrate and profile your printing equipment to ensure consistent color output. Use color management tools and software to match colors accurately, and perform regular color checks to maintain consistency across prints. This will help ensure that your prints meet the desired color accuracy and consistency, providing a professional and cohesive look for your finished products.

Finishing and Post-Printing Processes


Laminating the prints with a clear protective film can enhance their durability and resistance to scratching, fading, and weather elements. Lamination also adds a glossy or matte finish, depending on the desired effect. It helps protect the printed design from moisture, UV rays, and physical damage, making the prints suitable for long-term outdoor use. Choose lamination films specifically designed for corrugated plastic and follow the manufacturer’s instructions for proper application.

Die-Cutting and Perforation

Die-cutting and perforation are common finishing processes used to create custom shapes, cutouts, or perforated lines in corrugated plastic prints. Die-cutting involves using a sharp metal die to cut through the material, while perforation creates a series of small holes along a designated line. These processes add versatility and functionality to the prints, allowing for easy assembly, folding, or detachment of specific sections. Consult with a professional die-cutting service to ensure precise and accurate results.

Scoring and Folding

Scoring is the process of creating indentations or creases on the corrugated plastic to facilitate folding or bending. This is particularly useful for creating boxes, displays, or three-dimensional structures. Scoring ensures clean and precise folds without damaging the printed design. Use specialized scoring tools or consult with a professional printing service to achieve accurate and consistent scores that align with your desired folding or bending requirements.

Troubleshooting Common Issues

Ink Smudging or Bleeding

If you encounter issues with ink smudging or bleeding on your corrugated plastic prints, there are several potential causes and solutions. Ensure that the ink is properly dried or cured before handling the prints to prevent smudging. Adjust the ink density and print settings to achieve the optimal ink coverage, avoiding excessive amounts that can lead to bleeding. Additionally, check the compatibility of the ink and substrate, as using incompatible materials can result in poor adhesion and ink migration.

Poor Adhesion and Ink Peeling

If you notice poor adhesion or ink peeling off the corrugated plastic, it is important to address the issue promptly. Verify that the corrugated plastic sheets are properly cleaned and treated before printing to ensure optimal ink adhesion. Consider using primers or coatings specifically designed for corrugated plastic to enhance adhesion. Additionally, double-check the compatibility between the ink and substrate to ensure they are suitable for each other. If the issue persists, consult with a printing professional or ink supplier for further guidance.

Color Inconsistencies and Mismatched Pantones

When encountering color inconsistencies or mismatched Pantones in your prints, it is crucial to review your color management workflow. Ensure that your printer is properly calibrated and profiled to achieve accurate color reproduction. Verify that the color settings in your design software match the intended color output. If specific Pantone matching is crucial for your project, consult with a professional printing service to ensure accurate color matching and reproduction.

Best Practices and Case Studies

When it comes to printing on corrugated plastic, following best practices can help you achieve exceptional results. Here are some recommendations:

Test Prints and Color Swatches

Prior to large-scale printing, always conduct test prints and create color swatches to verify color accuracy, ink adhesion, and print quality. This allows you to make necessary adjustments or corrections before proceeding with the final prints.

Collaborate with Printing Professionals

If you’re new to printing on corrugated plastic or have complex requirements, consider collaborating with experienced printing professionals. They can provide valuable insights, recommendations, and troubleshooting assistance to ensure that your prints meet your expectations.

Regular Maintenance and Cleaning

Maintain your printing equipment and cleaning processes regularly to ensure optimal performance and print quality. This includes cleaning printheads, replacing worn parts, and calibrating the equipment as needed. Proper maintenance helps prevent issues such as clogged nozzles, inconsistent ink flow, or print defects.

Let’s explore some case studies where corrugated plastic printing has been successfully utilized:

Case Study 1: Event Signage

A local event management company used corrugated plastic printing to create eye-catching and weather-resistant signage for outdoor events. By utilizing vibrant colors, large fonts, and bold graphics, they were able to attract attention and effectively convey event information. The durability of corrugated plastic ensured that the signage remained intact throughout the duration of the events, even in adverse weather conditions.

Case Study 2: Product Packaging

A food manufacturing company opted for corrugated plastic packaging for their perishable products, such as fruits and vegetables. By incorporating their brand colors, logos, and product information onto the packaging, they were able to create a visually appealing and informative solution. Corrugated plastic’s resistance to moisture and UV rays ensured that the packaging remained intact and aesthetically pleasing, even during transportation and storage.

Case Study 3: Trade Show Displays

A technology company utilized corrugated plastic printing to create innovative and portable trade show displays. By incorporating intricate designs, die-cut shapes, and three-dimensional elements, they were able to capture attention and stand out among competitors. The lightweight nature of corrugated plastic made it easy to transport and assemble the displays, while its durability ensured that they remained intact throughout multiple trade shows.

In conclusion, printing on corrugated plastic offers endless possibilities for businesses and individuals looking to create eye-catching and durable prints. By understanding the materials, equipment, and techniques involved, you can ensure that your prints stand out and effectively convey your message. Whether you’re a novice or an experienced printer, this comprehensive guide has provided you with the knowledge and insights needed to excel in the world of corrugated plastic printing. So, get ready to unleash your creativity and take your printing projects to new heights!

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