Digital Can Printing 101: What It Is, How It Works, and Why It Matters 

By JP Purcell – https://www.linkedin.com/in/jp-purcell/ 

Learn the difference between traditional offset-printed cans and digitally printed cans. Find out how East Coast’s digital process gives brands more speed, colour, flexibility — and with Bulletproof, near-equal durability. 

Let’s break it down 

Not all cans are created the same — and not all are printed the same either. If you’re new to packaging or just wondering what makes a digitally printed can different from the traditional ones you see on supermarket shelves, here’s the quick explainer. 

Offset Printing (The Traditional Way) 

Offset printing has been around for decades. It’s the method used to produce the majority of cans you see in your fridge — think Coca-Cola, Boss Coffee, or Tooheys New. 
 
Here’s how it works: 
– Aluminium sheets are printed on using offset plates and rubber blankets. 
– Each colour is applied one at a time — like screenprinting a T-shirt. 
– The printed sheet is then coated and cured before it’s formed into a can shape (called “necking”). 
– Each design requires expensive plates and tooling, and has long setup times. 
 
Colour Limitations: Most offset cans are limited to 6–7 spot colours per design. 
MOQs: Often 30,000–100,000+ units per SKU. 
Lead Times: Expect months. 
Cost Efficiency: Cheaper at high volumes. 
Durability: Very high — think of how long a Coke can lasts in a vending machine or beach bag. 

Digital Printing (The East Coast Way) 

Let’s talk digital — specifically digital direct-to-vessel printing, which is what we do at East Coast. 
 
Here’s how our process works: 
– We print directly onto the can, after it’s already formed and necked. 
– Using advanced CMYK digital printing, we can print full-colour artwork in one pass — no plates, no setup time. 
– You get cans that are ready to fill within days, not months. 
 
Colour Range: Over 16,000 colours per design. 
Tiny MOQs: Just one layer per artwork (approx. 389–506 cans). 
Fast Turnaround: Days or weeks, not months. 
No Plates or Tooling: Artwork can be changed anytime. 
Cost per Unit: Slightly higher than offset at scale, but better inventory efficiency. 
Durability: Historically weaker — until now. 

Introducing Bulletproof: Durability, Solved 

Thanks to our Bulletproof innovation, East Coast is now home to the world’s most durable digitally printed can. 
 
– Enhanced abrasion resistance 
– Improved scuff protection 
– Designed for Australia’s tough supply chain 
 
Bulletproof cans now rival offset in durability — but without the MOQ, colour, and speed restrictions. 

So, which one should you choose? 

If you’re producing millions of cans of the same SKU repeatedly, offset printing makes sense. 
 
But if you’re: 
– Launching NPD 
– Testing new markets 
– Doing limited editions 
– Customising by state, retailer, or event 
– Working with multiple SKUs or collabs 
– Trying to stay nimble with your inventory 
 
…digital is the better choice — especially with Bulletproof. 

In Summary 

Want to see the difference for yourself? 

We’d love to show you how it works — and what your brand could look like on a digitally printed Bulletproof can. 
 
Contact our team or request a sample.