Resources · Free tool
Flexo vs Offset — label cost.
Price the same self-adhesive label on reel-fed flexo and sheet-fed offset. We'll show each per-label cost, which wins, and the break-even volume — including how offset's plate wear changes the picture on long runs.
Indicative estimate · printing cost only · for guidance only
How it works
How the comparison works
The tool prices one label job on a reel-fed flexo press and on a sheet-fed offset press. Flexo prints from the roll; offset prints sheets, so its side counts sheets, sheet size and plate wear.
- Plates
- Flexo plates are priced by area and usually last the whole job. Offset plates have a flat cost each and wear out, so the tool adds a fresh set each time the run passes the plate life you enter (30,000 sheets if left blank).
- Material
- Flexo uses label stock across the printed web. Offset uses the sheets your job needs, at the sheet size you enter.
- Ink
- By number of colours, coverage and price on both presses.
- Machine time
- Flexo in metres per minute, offset in sheets per hour, charged for electricity, manpower and each press's price as an EMI at 10% a year over 7 years.
- Break-even
- The order quantity where both processes cost the same per label.
Printing labels on rolls? See the Nova A5 and NovaSMART label presses on the products page, or the multi-substrate Nova A8.
FAQ
Flexo vs offset — questions
Is flexo or offset cheaper for labels?
It depends on the run length. Sheet-fed offset carries plate and make-ready costs plus plate wear on long runs, while reel-fed flexo has lower set-up and runs economically at short-to-medium volumes. This tool prices the same label on both and shows the break-even quantity.
What is the break-even quantity?
It's the order quantity where the two processes cost the same per label. The tool works it out from your inputs, factoring in offset plate wear (fresh plate sets as the run grows).
Is this comparison tool free?
Yes. Enter one label job, see both per-label costs and the verdict on screen, and get the full breakdown by email — free.
How accurate is it?
It's an indicative comparison from your inputs and typical rates, for guidance. Send us the details and we'll firm up the numbers.
Why does offset plate cost rise with run length?
Offset plates wear out, so long runs need fresh plate sets. The tool assumes one set lasts the plate life you enter (30,000 sheets if you leave it blank) and adds sets as the run grows. A flexo plate set usually lasts the whole job.
What's the practical difference between reel-fed flexo and sheet-fed offset for labels?
Reel-fed flexo prints, die-cuts, strips the waste matrix and rewinds finished labels on a roll in one pass, ready for automatic applicators. Sheet-fed offset prints sheets that then need cutting or die-cutting as a separate step, which suits cut-and-stack and wet-glue labels.