How DOD Inkjet Printing is Revolutionizing Product Packaging in 2025 The packaging world is observing significant shifts in how products are marked, coded, and made to stand out. Among technologies gaining ground, Drop-On-Demand (DOD) inkjet printing is proving to be a strong contender in packaging work in 2025. This method of printing brings together precision, cost-savings, and flexibility, enabling brands to address varied substrate challenges — from plastic and metal to uneven or porous surfaces. Companies seeking consistency, speed, and quality are turning toward DOD inkjet printing more than ever. What Is Drop-On-Demand Inkjet Printing? Drop-On-Demand is a classification of inkjet printing technology where ink drops are released from the printhead only when required, rather than continuously. Two common types are thermal and piezoelectric (piezo). In thermal DOD, heat causes vaporization of a small volume of ink to form a bubble, which forces a droplet out through the nozzle. In piezo DOD, mechanical or piezo-electric pressure pulses push out droplets. Needham Ink Technologies, in its “DOD Ink” line, produces British-manufactured Drop On Demand inks engineered for industrial use, combining fast drying times, strong adhesion, and high performance across porous and non-porous substrates. Needham Ink Why It’s Gaining Traction in Product Packaging There are several reasons DOD inkjet printing is increasingly adopted in packaging throughout 2025. 1. Reduced Label Costs Because DOD inkjet can print directly onto items (cartons, boxes, cans), there’s no need for separate labels. That removes label purchase, label design, label inventory, and label application costs. It simplifies supply chain steps. Needham highlights this as a key savings. Needham Ink 2. Flexibility of Substrates Modern packaging uses many materials: cardboard, plastics, metals, glass, even wood. Some are porous; others are non-porous or have uneven surfaces. DOD inks from Needham are designed to adhere well to both porous and smooth, impermeable surfaces. That means producers can use a single printing system to handle multiple packaging types. 3. Large Character Printing & Readability Nozzles in DOD printers often allow for larger font or character sizes. That helps when marking large surfaces or needing codes or batch information that must be legible even from a distance. Combined with high-quality drop formation, the resulting text or graphics are clean and easy to read. 4. High Speed and Reliability Packaging lines in 2025 demand speed — fast throughput, minimal downtime. The DOD inks from Needham are produced in the UK under high standards, with rigorous testing and consistent performance. Their long shelf life and compatibility with major DOD printing systems help keep production continuous. 5. Better Quality Over Challenging Surfaces Some packaging has curves, textures, coatings. Traditional printing may smudge, bleed, or fail to adhere well. DOD inkjet printing , with special formulations, achieves high print quality even on sensitive or uneven surfaces. It manages adhesion and curing in ways that reduce defects. Needham’s DOD inks are promoted as performing well here. Needham Ink 6. Improved Throughput and Less Waste Since drops are only ejected when needed, there is less ink waste compared to systems that fire continuously or overspray. Also, fewer misprints due to labels misaligned or damage to label materials. This contributes to cost savings and less downtime. In industries where packaging speed matters (food, beverage, consumer goods), that is a real benefit. Trends in 2025 Leveraging DOD Inkjet Printing As brands and manufacturers adopt DOD inkjet printing, several trends are clearly visible. Customization and Personalization at Scale Brands are offering limited-edition packaging, seasonal graphics, or even customer-specific designs. DOD printing enables variable data printing — batch numbers, dates, names — without needing different labels for each run. Flexibility comes with reduced overhead. Sustainability Pressures Removing labels reduces materials used and also adhesives. Inks that are formulated for less environmental impact, faster curing, lower VOCs, etc., are in demand. DOD inkjet printing supports this by enabling printing directly onto packaging materials, cutting out extra material use. Global Supply Chain Consistency Producers demand inks that work reliably in diverse environments — humidity, temperature, substrate types. In 2025, manufacturers are choosing suppliers with rigorous quality assurance. Needham’s inks, made in the UK, undergo extensive testing, and deliver consistent performance globally. Regulatory and Safety Marking As regulatory requirements increase (e.g. for food, pharmaceuticals), clarity of batch, date, coding becomes more important. DOD inkjet printing can apply precise codes that are durable, legible, and resistant to smearing or fading — features essential for compliance. Challenges and Considerations While DOD inkjet printing offers many advantages, several factors must be managed. Ink Formulation vs Substrate Compatibility Not all DOD inks are equally suited for all substrates. Adhesion on smooth surfaces (plastic, metal) is more challenging than on porous ones. Choosing the right ink formulation for the substrate is essential. Needham provides DOD inks suited for porous and non-porous surfaces. Drying Time & Environmental Conditions Fast drying is key in high-speed lines. If ink takes too long to dry or if environmental conditions (humidity, temperature) interfere, smudging or transfer may occur. Suppliers that control drying properties (e.g. quick cure) are preferred. Printhead Maintenance & Durability Printheads must resist clogging, misfiring, wear. Large character or larger nozzles help, but maintaining consistency over time (cleaning protocols, ink chemistry) matters. Cost of Ink vs Total Cost of Ownership While ink cost is one factor, equipment cost, maintenance, waste, downtime, operator training all contribute. The reduction in label costs must be weighed against any additional expense in system setup or maintenance. Case Use Scenarios in Packaging To see how DOD inkjet printing is changing the way packaging is done, here are a few real-life or hypothetical use cases in 2025. 1. Carton Marking in Food & Drink A beverage company printing batch numbers, best before dates directly on cardboard cartons. The cartons are porous and somewhat uneven. A DOD system using Needham ink can print clearly even over the ridges, with ink that dries quickly to prevent smudging during handling. The company saves cost by avoiding pre-printed cartons or labels. 2. Metal or Plastic Containers Cosmetic or chemical manufacturers using plastic or metal containers need durable codes. The direct high adhesion and ability to print non- porous surfaces means DOD inkjet printing can handle this. No label peeling, less risk of code loss in transport or moisture. 3. Promotional Packaging and Seasonal Runs Retail brands seeking holiday or festival graphics and limited edition packaging runs can now use smaller print jobs with varied designs directly on standard packaging, reducing inventory overhead, instead of producing large batches of custom labels. 4. Regulated Products Pharmacies, medical supplies, or food producers that have heavy compliance requirements need clear legibility, non-toxic inks, stable marking that survives cold storage or harsh conditions. With the right ink formulation, DOD printing meets those demands. What to Look for When Choosing a DOD Ink Supplier To realize the full benefits of DOD inkjet printing in packaging, it is important to select a reliable supplier. Consider the following criteria: Manufacturing Quality & Testing — Inks made under good quality control, lots of lab testing, consistency batch to batch. Compatibility with Existing Printing Systems — Ensure the ink works with your printheads or DOD printers (OEMs). A supplier like Needham offers inks that are compatible with many major OEM models. Drying Properties and Adhesion — Particularly if you deal in high throughput or use non-porous materials. Shelf Life & Storage Requirements — Inks that degrade or change over time reduce reliability — look for stable formulations. Environmental, Regulatory Compliance — Food safety, VOC levels, safety of ink chemicals, etc. Looking Ahead: What 2025 Means for Packaging with DOD Printing In 2025, packaging is no longer just about enclosing a product — it’s about communication, sustainability, and operational efficiency. The pressure to do more with less — less cost, less waste, shorter turnaround times — is intense. DOD inkjet printing puts many of those levers within reach: Brands are demanding traceability, variable data, and shorter runs. Sustainability goals push toward reduced waste and materials. Faster time-to-market (custom packaging, regional variation) becomes more of a competitive edge. For producers who integrate dod inkjet printing into their packaging operations well, the dividends may be large: lower costs, better quality, more flexible operations, and the ability to adapt quickly to market demands. Conclusion DOD inkjet printing is playing a central role in how products are packaged in 2025. Its ability to print directly on a wide variety of materials, deliver legible and durable marking, and reduce reliance on labels makes it a practical and increasingly essential technology. When paired with high-quality ink supplies, strong technical support, and awareness of the trade-offs, businesses can harness its full potential. Needham Ink Technologies Contact us for more information on our range of Drop On Demand inks British-made, reliably tested, engineered for industrial product packaging.