Decals, stickers, and labels may sound similar, but each option differs slightly. And though the difference may be slight in some cases, it can still affect which option is best for which scenario.

In this article, we will define these differences clearly and show you each option’s benefits and disadvantages. By the end, we hope to give you a better understanding of the difference between decals, stickers, and labels so that you can make a more informed decision the next time you use one of these options in your packaging project.

Defining a Sticker, Label, and Decal

Now that you know each option differs from the other, what is a decal? What is a sticker? What makes them different? What are they best for? You might have many questions that now need answering, but let’s first focus on the basic definition of a sticker, label, and decal. A better understanding of each option will allow us to give a much more accurate answer to each preceding question.

To begin, let’s look at the sticker. Custom stickers are small pieces of paper, vinyl, or fabric with an adhesive backing. They are available in various colors, shapes, and designs, making them versatile for branding and decoration.

Source: PakFactory

Decals are similar in that they have a self-adhesive backing but are larger, more permanent, and often used for identification and branding. They are typically made from vinyl, are cut to a specific shape, and have clear backgrounds to blend in when applied to various surfaces.

Source: PakFactory

Finally, custom labels are also a self-adhesive option made from materials like paper, vinyl, and polyester, but their usage is neither for decoration nor identification. They are usually printed with text or images that contain information about a product, its content, or its usage.

Source: PakFactory

As you can see from the above definitions and images, stickers, labels, and decals are similar in that they are all meant to stick to surfaces. Still, their intended purposes are generally different, and these differences don’t end there, so let’s dive deeper.

Decal vs. Sticker vs. Label

We briefly mentioned the different intended purposes for each adhesive option, but they also differ in other aspects. Though there are definitely similarities between the materials used and the types, styles, and production processes, it is essential to note the differences too.

Below, we’ve provided a simple chart to showcase the main differences. However, we will also go more in-depth to give you a complete picture of why stickers, labels, and decals should be considered separate adhesive options.

Differences in Materials

First, let’s look at the materials. We also briefly mentioned materials in the definitions section, but we’ll look at this topic in more detail here.

Source: Unsplash

For stickers, various materials are possible, like glossy paper, matte, vinyl, or fabric. Stickers are the most versatile when choosing materials and have many options for different intended looks, durability, and costs. For example, paper stickers are the most affordable option but are less durable than vinyl stickers.

Source: Jason Leung

Decals, however, typically use vinyl materials, which are durable,  weather-resistant, and highly customizable with colors and designs. This is necessary as decals are generally much larger and, depending on their usage, can be exposed to more weather elements than stickers.

Source: Natasha Kendall

Labels use similar materials to stickers but are usually thinner for easy mass application onto products. Common labeling materials include Biaxially-Oriented Polypropylene (BOPP), vinyl films, or paper. However, other materials like holographic or metallic are still possible, though rare.

Design, Application, and Durability Comparison of Stickers, Labels, and Decals

Regarding design options, stickers, and labels are very similar. They come in various sizes and have many design possibilities to suit different needs ranging from small and round adhesives to large and rectangular or even full-color printed designs. Both options are also available as a die-cut (cut to the exact shape) or a kiss-cut (cutting the material and leaving the backing paper untrimmed).

Where the similarities end, however, are in their application and durability. Stickers are typically applied manually, whereas labels can be applied manually but are generally mass applied through a specialized machine. On top of this, stickers can last much longer than labels depending on the materials, as labels are produced much thinner to accommodate mass application.

Source: Олександр Луценко

Decals are slightly different. As the largest of the three options and typically exposed to more outdoor elements, they are also the most durable. But unlike stickers and labels, decals are only available die-cut but can be designed in various shapes and sizes to work on surfaces ranging from glass, walls, metal, or sidewalks.

Source: Jan

Furthermore, leaning to its more prominent design, applying decals requires manual precision to ensure proper application with no lingering air bubbles. Therefore, it is highly recommended to seek the aid of professionals so that your decal is applied correctly!

Pros and Cons of Each Option

Now that you know the differences between stickers, decals, and labels, let’s examine the advantages and disadvantages to know which adhesive option works best for your next project. Below, we’ve compiled a list of the main pros and cons for each adhesive option:

When to Use Decals, Labels, or Stickers

With the benefits and disadvantages covered, you might still wonder when is the best time to use each option.

Stickers are best used to promote a brand. They are often included in product packaging to encourage customers to decorate their personal water bottles, notebooks, or laptops with your company’s branding. Stickers are also excellent for generating word-of-mouth and can even be sold as an individual product too!

Learn more on how to make and sell stickers online here!

Labels are used in many industries like food, retail, and pharmaceutical industries. They are meant to be put on the product or packaging itself and serve two purposes of brand identification and relaying important product information. Great product labels should attract attention while properly conveying product information to consumers, like expiration dates, ingredients, or usage instructions.

Finally, decals are for advertising a brand or displaying information. Because of their large and durable nature, decals are best utilized on signage, windows, walls, floors, large industrial equipment, or vehicles.

Similar, But Ultimately Different

Decals, stickers, and labels may be similar in some ways, but there are enough differences to warrant considering them separate entities. Each adhesive option has its own benefits, disadvantages, and ideal usage scenarios, so using these terms interchangeably needs to be corrected.

Here at PakFactory, we have many options for custom stickers and labels. So if you have any more questions or would like help on your next design project, please contact one of our packaging specialists today!

The post Custom Decals, Stickers, and Labels – The Master Guide first appeared on PakFactory Blog.

The post Custom Decals, Stickers, and Labels – The Master Guide appeared first on PakFactory Blog.

If you’ve ever had a project designed or printed before on a commercial scale, you’ve probably heard of CMYK. Alone, these four letters don’t give much of a hint as to what they are and what they’re for, but knowing this is important for any print job you do.

For starters, you should know that CMYK is an acronym.

Source: PakFactory

What is it, and what does CMYK stand for?

CMYK is a color model that stands for Cyan, Magenta, Yellow, and Key (Black). It refers to the four primary colors of pigment used in four-color process printing and is the industry standard for all print-related mediums like brochures, documents, and packaging.

Source: PakFactory

The CMYK color model also refers to the entire color printing process, where every image is separated into the four primary color pigments of cyan, magenta, yellow and key (black) to create a combination of colors with a fraction of the ink.

Now, you may wonder why we use ‘K’ or Key when referring to black. Well, there are two main reasons for this. The first reason is that Johann Gutenberg, the printing press inventor, was also the first person to use key when referring to black, which has since carried on to the modern day.

The second reason is that ‘B’ denotes Blue in the RGB color system. RGB is different from CMYK and stands for Red, Green, and Blue and is a commonly used digital color space for screens.

CMYK vs RGB vs Pantone

With the introduction of another color system, it is essential to discuss their differences so you know which color system to use for which purpose. We’ve already mentioned RGB, but to get a complete picture, we will also include Pantone (PMS) in the comparison, as this is another standard color system you may encounter.

Let’s look at all the main features each color system brings to the table and if you’d like to learn more about the other color systems, please click their respective links below:

	CMYK Color System	RGB Color System	Pantone Matching System (PMS)
Method	Blends four colors to create new colors	Arranges color pixels to create new colors	Uses pre-mixed solid, single-color ink
Mediums	Printing	Digital screens	Printing
When to Use	Designs that consist of multiple colors	Any digital designs	When perfect color matching is required
Color Consistency	Difficult to match between print jobs	Colors will display differently between screens	Identical colors from print to print, but difficult between different mediums

CMYK Color System

• A subtractive color spectrum that uses ink to remove colors from a lighter background, like white paper. CMYK uses reflecting light to achieve the colors you see on paper.
• CMYK blends four colors (cyan, magenta, yellow, black) to create new colors, which is also known as the four-color process
• CMYK color space is commonly used in printed materials like documents, photographs, brochures and designs that consist of multiple colors.
• Printing with CMYK may result in slight color variations between each print, but it is much more affordable and quick than Pantone.

RGB Color System

• An additive color spectrum that directly uses light to display colors instead of using the reflection of light.
• RGB arranges red, green and blue to create new colors on the screen
• RGB color space is commonly used in digital mediums like televisions, computer monitors, phones and tablets.
• If you intend to print, RGB should be converted to CMYK before doing so or done in the CMYK color system instead – more on this later.

Pantone Matching System (PMS)

• Pantone has over 1000 shades of colors, allowing for a more extensive and exact range of unique color tones.
• PMS uses pre-mixed solid colors for printing to create identical colors from print to print, as known as spot colors
• Like CMYK, Pantone can be used for printed materials. It is best for branding or when exact color matching is required.
• Pantone offers more precision of color than CMYK, but the colors may differ between mediums depending on how inks are absorbed. For example, the Pantone color will look different between printing on paper and printing on plastic.
• Pantone is also much more expensive and time-consuming than CMYK. With PMS, you are essentially paying for each new color you use.

The Purpose of CMYK over RGB

Recall earlier that we recommended converting projects from RGB to CMYK before printing. The purpose of the CMYK color model derives from the inefficient use of the RGB color model in printing. This is because CMYK is explicitly intended for ink, while RGB is for a digital display.

With RGB, inks of three colors (red, green, blue) would need to be mixed to get white, which is usually the most dominant color for a document containing text, for example. Paper is already a white variation, so using the RGB system is ineffective for the sheer amount of ink printed on white surfaces.

That’s why the CMY (Cyan, Magenta, Yellow) color system became the printing solution! Cyan and magenta yield blue, magenta and yellow yield red, while yellow and cyan yield green. All three colors combined will then make key, or black. This immensely reduces the ink needed to print a wide range of designs and colors.

As shown in the figure below, CMYK subtracts colors instead of adding colors like RGB, which makes this color system utilize way less ink!

Read more about color matching here!

Converting RGB to CMYK

So now that you know why the CMYK color system is better than RGB for printing, how do you convert an RGB project to CMYK?

While most colors can translate well between the color systems, subtle color shifts should be expected. What looks like blue in RGB might look like purple in the CMYK color space. This is why we highly recommend designing any work intended for print using CMYK beforehand.

However, if your project is already in RGB, then the simple steps below will help!

1. Create a replica of your original image and open both copy and original in Adobe Photoshop. This helps give you a point of reference when converting your image.
2. Select the copy you want to convert and click Image > Mode > CMYK Color from the main toolbar at the top of the screen.
3. You are done! Refer back to your original RGB image and adjust colors as required.

We always recommend viewing a printed proof of your project before sending it to the printing press to avoid costly errors and ensure accuracy.

CMYK For Your Next Packaging Project

With RGB now exclusively for digital screens and Pantone an expensive alternative, the CMYK color system has become a popular choice for packaging as it consumes less ink overall while providing an accurate color output. 

For that reason, custom packaging is efficient with offset printing, flexo printing, and digital printing using the CMYK color system and creates consistent brand colors for exceptional branding opportunities.  

Still trying to figure out if CMYK is suitable for your packaging project?

Contact us today and find the perfect color-matching system for your custom packaging project! 

The post What is CMYK for Printing? first appeared on PakFactory Blog.

The post What is CMYK for Printing? appeared first on PakFactory Blog.

Source: PakFactory

Creating a lasting impression on your target market involves having attractive product packaging with a distinct “wow” factor. In that regard, the print coating is one of the most critical packaging elements you need to be aware of if you want your packaging to look its best despite multiple individuals touching and handling your products.

Whether used for packaging boxes, calendars, manuals, or other applications, the coating impacts the final look and appeal of the product.

And while each company has its own set of needs, to get you started, let’s look at one of the most popular coatings available: Aqueous (AQ) coating. But before we delve deeper into this excellent finishing method, you might wonder why you should apply a print coating to your project.

When to Coat?

Regardless of which coating you’re considering, in most cases, it will help protect and enhance your final product. If you intend to mail your piece, a print coating is necessary. And if you predict many hands will handle your print like a business card or brochure, a print coating is highly recommended for its added protection.

Source: Unsplash

However, sometimes your printed piece might be hindered by a print coating. Greeting cards, for example, do not need a coat, as applying one would make writing on the card challenging, defeating the intended purpose of your greeting cards! Still, if you wish to add a print coating to these items, you must specify with your service provider the areas where a coat should not be applied to avoid this problem.

But now that you know when is a good time to use coatings, let’s get back to the main topic at hand.

What is Aqueous (AQ) Coating?

Unlike UV coating and varnish, AQ coating is water-based and is known as the “default” coating for printing and packaging. It features fast-drying capabilities when used during the printing process, which makes it possible to achieve different appearances, allowing various application methods.

In addition to this versatility, AQ coating is known for being environmentally friendly with its non-toxic, water-based solvent that makes it perfect for applications such as:

• Foods
• Household products
• Fast-moving consumer products

Source: PakFactory

AQ coatings are also resistant to fingerprints and other impurities during handling, and it is also possible to enhance surface durability with a combination of different coat layers. However, the product type will largely determine the suitability of AQ coating for your packaging. 

Remember that though this coating is water-based, it does not mean it is waterproof!

Cosmetic products and perfumes, for instance, contain chemicals that may make AQ coating challenging to maintain on the exterior or interior of the packaging due to the risk of leaking, so always consider the product and your needs when deciding on the best print coating for you.

To help you better determine this, we have included some key differences and features between the popular options of AQ coating, UV and varnish.

	AQ Coating	UV Coating	Varnish
Coating Area	Flood coating only	Flood or spot coating	Flood or spot coating
Drying Speed	Fast drying	Instant drying	Longest drying time
Solution Base	Non-toxic water based	Chemical based solvent	Water or chemical based solvent
Yellowing	Less likely to yellow	Do not yellow	Yellowing may occur
Finishing	Matte, satin, gloss	Matte, gloss	Matte, satin, gloss

1. Aqueous Coating

• It is only available as a flood coating that covers the entire printed material.

• It uses a fast-drying water-based solvent, typically making it the most cost-effective option.
• The non-toxic water-based solvent also makes it environmentally friendlier.
• AQ is durable and provides excellent protection from scratches, fingerprints and scuffs. It is also less likely to yellow than varnish and more flexible than UV coating, which can crack when folded or creased.
• Can have a matte, satin, or glossy finish.

2. UV Coating

• Available as a flood or spot coating, which allows highlighting of specific parts of your printing project.
• It uses a chemical-based solvent containing polyethylene (plastic) or calcium carbonate, which is less environmentally friendly than AQ coatings.
• As the name suggests, this option uses ultraviolet light to dry and harden the finish near instantly.
• Like AQ coating, UV can have a matte to glossy finish, but overall, UV coating results in a shinier finish than AQ. Some find the finish too shiny, but this shine can really make images pop.
• UV Coatings are chemical and water-resistant and do not yellow over time. They offer the most protection over the other options.

3. Varnish

• Varnish is available to flood or spot coat. However, they are heavier-bodied, meaning they can only be applied to specific areas via press-plate, and detailed artwork must be sent to the service provider prior to the job.
• Uses a clear liquid that can be UV or aqueous-based to cover the surface of printed material in a manner similar to an ink printing press.
• Varnish uses UV light or heat to dry but takes much longer than the other options.
• Varnish is also available in matte, satin, or gloss finishes.
• Varnishes protect your printed piece very well, but yellowing may occur. Areas not varnished are more susceptible to yellowing over time.

If the other options seem more appealing to your printing project needs, please visit our UV coating or varnish articles to learn more. If not, then let’s continue our journey into aqueous coatings!

The Benefits of Aqueous Coating

We’ve briefly mentioned the benefits AQ coating has over the other popular finishing methods, but let’s look at the four main benefits in more detail to understand why so many companies choose this option.

• Non-toxic & environmentally friendly: The treated paper is easily recyclable and does not produce harmful by-products. After applying the aqueous coating, there is minimum solid waste, and the cleaning process does not require toxic cleaning agents.
• Versatile: It is a no-hassle solution when additional finishing is necessary to the print and works well with various printing processes. The coating also makes it very easy to write and print over the coating for more variety in finishes.
• Cost-effective: This water-based coating is mainly used in line with the printing process, delivering significant cost savings.
• Durable and long-lasting: By sealing the ink against exposure to air, the coating maintains the fidelity of metallic inks. Aqueous coating is also less susceptible to yellowing, making it a better alternative to varnish.

Types of AQ Coatings

As mentioned previously, aqueous coatings are available in matte, satin or gloss finishes, but other unique coating types are also available to fit your printing needs! Let’s have a look.

Gloss: A gloss aqueous coating is ideal if you’re looking for a less showy and more muted finish. As mentioned above, UV coating or film laminates are better options if you are looking for a flashier shine.

Dry erase: An alternative to laminate, dry-erase AQ coating achieves a high gloss effect at a low price.

Satin: With an appearance between gloss and matte, a satin aqueous coating offers medium shine and excellent scuff resistance.

Matte: A matte aqueous coating offers minimal shine and depth but a high degree of color intensity.

Soft Touch: Soft touch aqueous coating creates a velvety texture with a soft appearance compared to a glossy finish. Similar to matte coating, it gives a subtle finish with little to no shine.

The Aqueous Coating Process

Now that we know the different coating types of this popular print coating method, what is the application process? 

Put simply, special machines apply the aqueous coating immediately before printing ink on the sheets. Special care is taken to ensure no wrap, wrinkles, or curls occur on the paper during this process and after the application of the coating, the sheet passes through a heated air system for quick drying.

The video below is a great visual example of how this process is done.

The Final Coat for AQ

Although AQ coating provides several benefits, the chances of chemical burning with aqueous coating and UV coating are higher than other finishes such as varnish.

The solvent resistance of the aqueous coating is lower than that of UV coating and thermal lamination.

Nevertheless, AQ coating is still the most popular choice for print finish options thanks to its reliable and brilliant results.

Looking to learn more about your coating options for packaging?

Contact our product specialists today and get expert advice on finishing and printing options tailored to your product!

The post What is Aqueous Coating for Printing and Packaging? first appeared on PakFactory Blog.

The post What is Aqueous Coating for Printing and Packaging? appeared first on PakFactory Blog.

An Overview of Foil Stamping

Foil stamping is a specialty printing process that uses metal dies, heat and pressure, to apply foil films.

Foil stamping has a wide range of applications, including;

• Stationery
• Labels
• Product packaging
• Holiday cards
• Seals
• Pocket folders
• Postcards
• Certificates

Source: PakFactory

The modern technique, known as hot stamping, was first conceived in the late 19th century.

Today, it is leveraged to create visual interest and increase the perceived value of products.

A foil is a thin film coated with the colors that are applied to a product through a process known as hot stamping.

The pigment is placed on a clear film, which acts as a carrier that transfers the color onto the product.

Another layer of the foil consists of pigmented sediments, and a third layer is a heat-activated adhesive that sticks the sediments onto the product.

Like Embossing & Spot UV, you can apply foil stamping to all kinds of paper stocks.

It works best for stock with a smooth, even surface as opposed to textured or lined materials.

Types of Foil Stamping

Based on your substrate and the type of finish you want, you can choose from one of the four hot stamping techniques discussed below:

• Flat foil stamping, a simple, economical process where a copper or magnesium metal stamp transfers the foil onto the substrate. It achieves a foil design that relatively raises from the surface.
• Vertical foil stamping, which stamps foil designs on flat substrates and cylindrical shaped areas.
• Sculpted foil stamping, which uses brass dies to achieve a raised image for a clearly defined and carved look.
• Peripheral foil stamping, where foil heat transfers are applied to the outer perimeter – across the entire circumference – of the product.

Source: Sonhab Chocolate – PakFactory

Typically gold and silver coloring is used to create a luxurious effect.

Various finishes, such as glossy, matte, metallic, holographic sparkles and wood grains are available.

Types of Foils Used

There are different types of foils that can help create distinctive packaging/products in line with your marketing campaign or brand image.

Metallic foil, which offers an attractive patina across colors like silver, gold, blue, copper, red, and green.

Matte pigment foil, which has a muted appearance but an intense depth of color.

Gloss pigment foil, which combined high gloss with a non-metallic finish across a variety of colors.

Holographic foil, which transfers hologram images for a futuristic, eye-catching look.

Special effects foil, which can be used to create a range of textures, including mimicking the appearance of leather, pearl, or marble.

The Hot Stamping Process

Hot stamping is a machine-based process.

The foiling die on which your design is etched is heated and stamped with high pressure to bond a thin layer of foil to the substrate.

The application of heat and pressure is the core approach that delivers the desired result on the substrate.

The die can be made of brass, magnesium, or copper.

Though it is an expensive purchase, it offers multiple uses and is therefore worth the initial investment.

The Benefits of Foil Stamping

As foil stamping doesn’t use ink, the foil color is not impacted by the color of the substrate upon which the design is applied.

Foils in light and metallic colors can be easily used on darker colored papers.

You can achieve a range of finishes with hot stamping, allowing you to experiment with your branding and packaging.

The striking effect possible with this technique also makes it a good solution to stand out from the sea of competitor products.

For other print finishing options, you can check out: Embossing & Debossing, Spot UV, Window Patching & Soft Touch.

Foil stamping has great potential to elevate and breathe new life into existing packaging designs.

Whether it’s to add a little pizazz to your logo or enhance your artwork designs, foil stamping gives your products and brand a higher perceived value.

Working with a product specialist allows you to optimize your packaging in every aspect from structure to artwork.

The post What is Foil Stamping? first appeared on PakFactory Blog.

The post What is Foil Stamping? appeared first on PakFactory Blog.

Are you considering a folding carton for your product packaging? If you are, you’ve come to the right place to learn everything you need to know about this option! These foldable paper boxes are a trendy and versatile choice for many industries. Though these boxes are commonly seen as a paper packaging option for food, it is viable for pharmaceuticals, cosmetics, and electronics.

Source: HRBLS by Pharmakon Supernatural – PakFactory

The paperboard material is excellent for customizing your package’s size, shape and structure to accommodate any product.

So in this article, we will delve deep into what makes a folding carton tick starting with its definition, the common materials used, styles available, production method,  and some pros and cons of this type of packaging. By the end of this master guide, we hope to have provided you with sufficient knowledge to decide whether this paper carton packaging option suits your product.

What is a Folding Carton?

Before we take a closer look into this versatile packaging option, what exactly is it? Well, folding cartons are a type of paperboard packaging popular among consumer products for their low weight and versatility.

It is commonly used as secondary packaging, and as the name suggested, these foldable paper boxes are designed for easy assembly from a single flat sheet into a three-dimensional package, making them cost-effective to transport because they are shipped flat before being assembled while maintaining a high level of customizability.

Folding Cartons vs Rigid vs Corrugated

But what are the differences between the similar and equally popular packaging options of rigid and corrugated boxes? To get a better understanding of the key differences between each option, we’ve provided a simple chart below:

	Rigid Boxes	Folded Carton Boxes	Corrugated Boxes
Set up	None if not foldable	Needed	Needed
Sturdiness	High	Low	High
Product Safety	High	High with the aid of inserts	High
Cost	Generally High	Depends on printing & finish	Depends on printing & finish
Appeal	Generally High	Depends on printing & finish	Depends on printing & finish
Reusable	Yes	Usually not	Yes

Folding Carton Packaging Materials, Types & Styles

In terms of materials, the most common materials used for manufacturing standard folding cartons are paperboard made from wood pulp, a renewable and environmentally friendly resource. However, higher-grade, certified paperboard options that meet food and even medical standards are also available!

Alternatively, to increase eco-friendliness, kraft paperboard made from 100% post-consumer recycled material or reclaimed paper stock is also a popular option. And if you thought the material options offered a lot to consider, a wide selection of styles and different types of boxes are also available. In this master guide, we have provided you with the seven most popular options; let’s have a look!

The tuck end auto-lock bottom box, or crash bottom box, has a bottom design that automatically locks in place during assembly with a simple tuck flap. This box style is recommended for heavier products, like wine and beer, as it is the strongest among all paper box packaging options listed below.

Alternatively, the snap bottom or lock bottom box is another strong option suitable for heavier objects like wine or electronics. Also known as the 1-2-3 bottom box, this box style has flaps that push into each other and lock in place.

Straight tuck end boxes are stored flat and do not require additional assembly. They are identified by having both the top and bottom closures on the same side of the box and slits on the ends to keep the tucks locked. This style is ideal for light or medium-weight products like cosmetics or essential oils.

Reverse tuck end boxes are the same as straight tuck but have the end closures on the opposite sides of the box. Since they are nearly identical, reverse tuck boxes are also ideal for light or medium-weight products.

Paper sleeve packaging is a carton style designed to slip over another, typically undecorated box. This option is a very popular choice due to being the least expensive option and can instantly create fantastic customization for a plain box.

Double wall tray and lid boxes, or two-piece boxes are separated with a top and bottom half. The tray and lid fit snuggly together to create a sturdy double wall ideal for luxury products like jewelry and clothing or serve as food packaging for products like confectionery.

Customized folding carton boxes are the final popular option. Who said foldable cartons needed to be a certain way? Custom cutouts and inserts for the above options are limited only to the imagination. A well-placed cutout or insert can add a unique flare to your packaging, differentiating itself from competitors!

Whether using folding carton boxes as a paper food packaging solution or for other items like cosmetics and electronics, the styling options are limitless. From choosing kraft paper packaging for eco-friendliness or utilizing a two-piece box for added luxury, these foldable paper boxes are an excellent option for any product!

Manufacturing Processes

Regardless of the materials or style you choose for your carton packaging project, the process of making folding cartons remains the same. Once you’ve finalized your design choices for your box, it is time to let your packaging supplier get to work with the below list of elaborate processes known collectively as converting:

1. Die-Lines and Sheet Layout: Die-lines are flat versions of the box showing what the final 3D box will look like. It shows the locations for die-cutting, folding and gluing while also showing the position of the artwork on the final package.
2. Sheeting and Printing: Large rolls of paperboard must first be cut into sheets before running through the printing press. Manufacturers will ensure that the grain is running in the direction that will be most efficient and effective for this step. When the sheet enters the press, any imagery and artwork you designed will be inked and coated onto the sheet via offset, digital or flexographic printing.
3. Post-Press Finishes: Further optional customizations like hot-foil stamping or embossing and debossing are done via specialized machines during this stage to enhance the look of your box.
4. Die-Cutting: This stage is where many duplicates of your carton are cut from the paperboard sheet. The die is a specialized, elaborate cutter akin to a cookie cutter that will cut the paperboard while minimizing waste and allowing for easy folding where necessary. The manufacturer recycles excess scraps of paper made from this stage to form new paperboards.
5. Folding and Gluing: The final stage of the converting process is where your box’s flat, die-cut pieces are fed through the machine for folding, pre-breaking and gluing. Some cartons that include transparent windows in the design are applied in-line during this stage. The manufacturer will aim to complete these processes in the fewest passes possible.

Pros & Cons of Folding Cartons

Now that we’ve gone over the intricate details of what makes a folding carton a popular and excellent choice for your packaging needs, what are the pros and cons of this option? Like the other popular options, there will always be benefits and downsides. Weighing these options is critical in deciding which packaging is best for you.

For starters, this packaging option can be cost-effective, sustainable and versatile. Carton boxes can come in many different shapes and sizes while being cheap to manufacture in large quantities. The materials used in this manufacturing process are also 100% recyclable, making them better for the environment.

Folding cartons also have a plethora of printing and unique finishing options available to choose from. As mentioned in this guide, printing options include offset, digital and flexographic printing, allowing excellent colors, unique textures and visual effects. For special finishes, this packaging option offers things such as:

• UV Coating
• Spot UV Coating
• Lamination
• Embossing/Debossing
• Die Cutting/Scoring
• Glitter/Pigment Sprinkles
• Foil Stamping

Even options for certified grades of paperboard material are available to accommodate food and medical industry standards!

But though these many benefits are heavily in favor of folding cartons, there are still a few minor disadvantages compared to other options. The strength and durability, for example, can be a disadvantage, but foldable cartons can still be solid and reliable with additional inserts. However, compared to the more sturdy rigid and corrugated boxes, they may not be as protective of the product inside.

Additionally, due to the limitations of cutting machinery, thickness is limited to 0.81 mm, which makes it difficult for this packaging option to hold significantly weighty products.

And though we did mention that folding cartons are sustainable, on the other hand, some packages tend to be challenging to assemble and are often improperly thrown away after a single use, increasing waste and counterbalancing the fact that this option should be eco-friendly.

Overall, this packaging option is excellent for many products, but always consider the pros and cons to ensure this option is right for you. That being said, what industries are these foldable boxes best for?

Suitable For Many, Best for Some

Source: PakFactory

The food and medical industries are the first thing that comes to mind when considering the industry that best suits foldable cartons. We mentioned earlier that this packaging option offers different grades of paperboard suitable to specific industry standards, and this is where that advantage shines through.

To learn more about paperboard grades, click here!

But to briefly summarize, with more expensive and highly durable paperboard grades available, like Solid Bleached Sulfate (SBS) and Folding Box Board (FBB), it’s no question why medical and food companies prefer the folding carton. Options such as various paper grades help protect sensitive products from dust and damage while keeping the product fresh longer.

Source: PakFactory

Other industries that greatly benefit from foldable box cartons include the cosmetics industry for its lightweight and attractive packaging designs and the electronic industry for its ability to protect from physical damage, dust and moisture.

But though these industries benefit the most from this packaging option, that doesn’t mean folding cartons are unsuitable for other products outside these industries!

Need help finding the right custom packaging for your industry? Browse here!

So Let’s Get Packing!

Even if you have a product outside of the industries mentioned above, the folding carton can still offer great benefits for your product. If you are still unsure if this packaging option is right for you or if you are ready to take the next step in your packaging project journey, contact one of our packaging specialists for more information!

The post Folding Carton Box Packaging – The Master Guide first appeared on PakFactory Blog.

The post Folding Carton Box Packaging – The Master Guide appeared first on PakFactory Blog.

Offset printing is a highly sought-after process across many industries because of its exceptional quality, making it an ideal choice for enhancing the value of various products, packaging, and publications. 

Unlike other printing techniques, offset printing is popular due to its ability to produce sharp, clear and consistent images that accurately depict the original artwork while maintaining the ability to print large volumes of materials efficiently.

But if you’re considering this printing process for your packaging project, it’s essential to understand how it works and what makes it a great option. So in this article, we’ll delve into these details, starting from the pre-press, printing, and post-press stages.

By understanding the ins and outs of offset printing, you can make an informed decision when deciding if it’s the right choice for your packaging project.

Source: PakFactory

What is Offset Printing?

Offset printing, or offset lithography, is a printing press technique that transfers ink from a plate to a rubber roller (or blanket) and then to various substrates to produce high-quality images and designs typically for mass production, such as printing large quantities of newspapers, brochures, stationeries, magazines, and of course, boxes.

For this reason, it is one of the most widely used printing options for its high-quality output and consistent results.

Source: PakFactory

Offset Lithography vs Digital Printing

Offset and digital printing are two distinct techniques with unique features and benefits. A detailed comparison is available via our Digital vs. Offset Printing article, but the main differences between the two include the following:

• Printing Process: Litho-printing uses plates to transfer ink onto a rubber blanket, which then applies the ink to the paper, while digital printing directly applies ink using an electronic file.

• Quality: Digital printing can produce good-quality images but does not match lithography’s sharp details and vibrant colors.

• Cost: For large print runs, offset lithography can offer a reduced unit cost with higher quantities. Digital, on the other hand, is better for smaller print runs.

• Turnaround Time: Digital printing has no plate setup time, and the printing process is faster.

• Customization: Digital printing allows for greater customization and personalization, including variable data printing, which offset lithography cannot achieve.

	Offset Lithography	Digital Printing
Printing Process	Transfer ink onto paper through rubber blanket	Prints directly on paper
Quality	Higher quality printing	Limited to 4 colour process printing
Cost	Price goes down at higher volume	Cheaper for low volume printing
Turnaround Time	Longer setup time and ink drying time	Faster turnaround time, less setup time
Customization	No variable printing due to pre-made ink plates	Different versions of variable printing allowed

Source: PakFactory

Overall, both techniques have advantages and disadvantages, so it ultimately depends on the specific needs that best fit your project. If you want to learn more about digital printing, we have you covered! However, if you want to continue learning about offset lithography, let’s move on to its various printing stages.

The Pre-Press Stage

The pre-press stage is a crucial step in the lithographic printing process that involves preparing digital files for the printing stage. This stage encompasses a range of activities, including designing, layout, and typesetting, which all play a crucial role in ensuring that the final printed product meets the desired specifications.

One of the key goals of the pre-press stage is to ensure that the digital files meet the specifications for the printing process, so during this stage, designers will work to verify fonts are appropriately embedded, the layout is formatted correctly and ensure properly formatted digital files for printing. This includes providing appropriately-sized files, correct file format, and that files are correctly color-managed. 

The pre-press stage also consists of making any necessary adjustments to the digital files to ensure that they will produce high-quality prints.

Source: PakFactory

Read more about how to prepare your dielines for print

Formatting digital files correctly and making necessary adjustments is essential because one of the most common mistakes designers make is not converting their work from RGB to CMYK, which ensures images are accurately coloured and of high quality and resolution.

So the best way to make sure you are preparing your files correctly is by contacting a product specialist of the packaging or printing company you are working with. They will help you through the pre-press stage, ensure the printing process runs smoothly, and that the final printed product meets the desired standards.

The Printing Stage

The next stage after pre-press is the printing stage, which involves using specialized offset lithographic printing machines that require equally technical operators to run correctly and transfer ink from printing plates to blanket cylinders and then to paper.

This process is highly efficient and can produce high-quality, consistent prints, making it a popular choice for commercial printing applications, and for good reasons!

One of the most significant advantages of litho-printing machines is their ability to handle a wide range of paper stocks, ink types, and printing plate sizes while producing high-quality prints with sharp, precise images and text. This advantage is possible because the ink transferred to the paper via the blanket cylinder allows for a more consistent and uniform application, as shown in the figure below.

In addition to the advantage mentioned above, these specialized machines can produce large print runs relatively quickly, further establishing offset lithography as an ideal choice for commercial printing processes and applications.

The Post-Press Stage

The final step of the litho-printing process is the post-press stage, where the offset materials are finished and prepared for distribution. This stage includes crucial activities such as cutting and finishing to ensure the final product meets the desired quality standards.

Cutting, which involves trimming the edges of the materials so they are uniform in size and the product looks neat and professional, typically uses a guillotine cutter that can simultaneously handle large stacks of paper. 

Source: PakFactory

Finishing involves adding special coatings or embossing to enhance the appearance of the offset materials. For example, a glossy or matte coating can give a professional, polished look. Conversely, embossing can add texture and depth to the design, making it stand out and catch the reader’s eye.

Quality Control and Inspection

When the printing process is complete, it’s time to move on to quality control and inspection, which is crucial in ensuring that the final product meets or exceeds the customer’s expectations.

To maintain the highest level of quality, post-press technicians use many various tools and techniques to inspect the finished products. This includes using colorimeters and densitometers to measure the color accuracy and consistency of the prints.

Source: PakFactory

Technicians also use magnifying lenses and microscopes to closely examine the printed materials for imperfections or defects, such as smudges, streaks, or misalignments. If any issues appear, they are promptly addressed, whether it involves reprinting the entire job or making minor adjustments.

Types of Offset Litho-Printing

Web Offset Printing

Web offset lithography is typical in the printing of newspapers and boxes. In this process, rolls of paper are fed continuously through the machine press and can produce over 5,000 printed materials. In addition, the paper is cut to create identical sheets during this process.

Web-fed offset printing presses can produce over 3,000 papers per minute, w translating to about 80,000 identical sheets per hour, which makes it an ideal option for organizations that need to have large quantities at a fast pace to meet tight deadlines.

Sheet-Fed Offset Printing

Unlike Web-fed, sheet-fed offset lithography produces smaller quantities as sheets of paper are fed individually to the machine. However, this method is still considered a quick printing option compared to other alternatives. 

Sheet-fed printing can produce up to 12,000 sheets to 24,000 per hour, but with modernization, this type of printing has significantly improved in speed, allowing it to perform similar functions as the web-fed press.

The Advantages and Disadvantages of Modern Offset Printing

Source: PakFactory

Advantages:

1. High Quality: This process produces high-quality images and text with excellent color accuracy and sharpness, making it an ideal choice for packaging projects that require a professional and eye-catching appearance.

2. Versatility: It can be used on various surfaces, including paper, cardboard, and plastic, making it a versatile printing technique for different types of packaging.

3. Cost-Effective: Litho-printing is cost-effective for large-scale production runs and has lower setup costs than other printing methods.

4. Consistency: Offset printing produces consistent results across large production runs, ensuring that the final product meets the desired quality standards.

Disadvantages:

1. Time-Consuming: Printing can be time-consuming, requiring several steps, including preparing printing plates.

2. Limited Customization: While offset printing is versatile, there may be better options for highly customized packaging designs. It may require additional setup time and costs to create custom printing plates.

3. Not Ideal for Small Runs: Litho-printing is not cost-effective for small production runs, as the setup costs can be high compared to other printing methods.

4. Environmental Concerns: Using chemicals in the printing process can have ecological implications. It may require proper disposal and handling to minimize their impact.

Is It Right for You?

Offset lithographic printing is a crucial and widely-used printing technique in various industries, including packaging. 

As technology evolves, offset printing will continue to play a significant role in the industry and provide new opportunities for businesses to create innovative and visually appealing packaging solutions.

So if you are considering using this printing technique for your next packaging project, you can feel reassured that this method will provide you with many options to create high-quality, versatile and cost-effective prints that will meet and exceed your requirements!

The post The Offset Printing Process: How it works first appeared on PakFactory Blog.

The post The Offset Printing Process: How it works appeared first on PakFactory Blog.

So without further delay, let’s start with the basics; what is it?

What are Rigid Boxes or Set-up Boxes?

Source: PakFactory

Custom rigid boxes are sturdy paper-based packaging comprising high-thickness (often 2-3mm) chipboard wrapped in decorative specialty paper. As mentioned earlier, they are commonly referred to as set-up boxes or premium packaging due to their luxurious look and feel, which goes perfectly with items such as board games, luxury products like jewelry, or gifts.

Furthermore, these custom boxes offer a premium feel that enhances your customer’s unboxing experience allowing for more opportunities to establish a strong brand narrative. It provides many branding capabilities through printing and finishing options, including;

• Hot stamping
• Embossing/debossing
• Coatings
• Decorative elements

The Difference Between Flexible, Corrugated, Folding Cartons and Custom Rigid Boxes

Now if you have researched and read up on the other different types of packaging that may suit your product, you likely have heard of other options, such as flexible packaging, corrugated boxes and folding cartons. You can probably guess how flexible and rigid diverges by their names, but corrugated and folding cartons may be harder to distinguish. However, to cover all our bases, let’s briefly review each option and how they differ. 

For starters, rigid boxes feature sturdy construction and support and are comparatively more luxurious in their look and feel. They are a trending packaging option consisting of thick chipboard and refer to solid packaging that won’t change shape, contrary to flexible packaging, which bends easily. 

However, differentiation becomes a little more challenging when looking at the other options, as they are very similar. While rigid boxes are often viewed in a league of their own when it comes to presentation, popular alternatives include folding carton boxes and high-end corrugated packaging because of their cost efficiency and versatility in high-quality printing and finishing capabilities. Let’s look at the differences;

	Rigid Boxes	Folded Carton Boxes	Corrugated Boxes
Set up	None if not foldable	Needed	Needed
Sturdiness	High	Low	High
Product Safety	High	High with the aid of inserts	High
Cost	Generally High	Depends on printing & finish	Depends on printing & finish
Appeal	Generally High	Depends on printing & finish	Depends on printing & finish
Reusable	Yes	Usually not	Yes

Source: PakFactory

As you can see from the above chart, the options are very similar and deciding which packaging solution to use is entirely up to you! So if you want to know more about the other options available, please read more about folding cartons or corrugated packaging. But if you are confident that this option suits your needs, let’s continue.

Types of Rigid Packaging

There are two different types of custom rigid boxes: partial finish and full finish.

A partial finish is where the wrapping and chipboard are only somewhat complete. The wrapping finishes the box’s outer surfaces, while the chipboard is left visible and bare. Partial finish boxes use a single piece of chipboard with perforated crease lines for folding and wrapping without the additional exterior layer that exposes the kraft or grey chipboard material. 

This option is used because it takes much less time to produce due to the fewer materials needed in the construction process.

Source: PakFactory

On the other hand, a full finish leaves no chipboard exposed; the wrapping covers the entire box. This option uses a thicker 2-3 mm chipboard, and the inner chipboard is separated into pieces for each side of the box. Lamination is also possible with various finishing options depending on needs.

Full finish packaging also has an additional layer of wrapping, which is white by default or printed.

Source: PakFactory

So, in Summary:

Partial Finish:

• Wrapped only to finish the inner edge of a box
• Chipboard inside is unfinished and visible
• The internal chipboard is one piece with perforated crease lines and folds
• Tape is optional to secure the chipboard before wrapping
• Chipboard finish can come coated on one side using white or kraft

Full Finish:

• Wrapped entirely. No chipboard exposed
• The inner chipboard is in separate pieces for each face of the box
• No tape before wrapping boxes
• Thicker chipboard (or greyboard) at 2 – 3 mm thicknesses
• Laminated with different finishing options

How Is It Made?

But how do rigid boxes reach this finished state? To keep things simple, we have split up the process of constructing one of these high-end boxes into four simple steps that apply to both options:

1. Sizing – The box starts as a flat paperboard that is first cut and scored to the correct size.

2. Folding – The paperboard is then folded and secured to form the base of your box.

3. Printing – A design is printed onto the wrap and laminated. Other add-ons can be included as you desire. The wrap is then glued to the shape of your box.

4. Wrapping – The wrap tightly covers your box, and we are done!

If you are still unsure of the process to complete your box, the below figures should help paint a clearer picture:

Source: PakFactory

Various High-End Packaging Styles

Not only do custom rigid boxes have two different types available to choose from, but there are also many style options as well! Let’s have a look at some popular options.

Tube or rolled-edge tube packaging is a cylindrical packaging option. It comes in telescopic or shoulder-neck opening styles, making it ideal for drinks, cosmetics, accessories, and snack containers like Pringle’s cans.

Magnetic closure boxes boast two sturdy magnets that effortlessly seal the box shut, adding a touch of luxury to jewelry and retail products. With their tactile closure, these versatile boxes can also be collapsible for convenient and friendly storage.

Drawer Style Boxes, as the name suggests, open up like a drawer. They are also known as slipcases, slides or matchboxes.

Book Style Boxes open like a hardcover book, adding creativity and innovation. With a straight or rounded spine, they provide a genuine book-like feel. Magnetic attachments can also be combined, creating a luxurious packaging option.

Shoulder Neck Boxes have multiple layers, including a distinct inner layer for the lid to rest on. Perfect for a unique unboxing experience, these boxes can be customized to match your brand’s colors and style.

Browse our full catalog of rigid box packaging here!

Inserts To Compliment Styles

The choices are limitless when it comes to styles of rigid boxes, but once you have decided on the type you prefer, the next step is to think about what inserts will go inside. 

Additional packaging materials like box inserts are very popular when designing rigid packaging. Packaging inserts are highly recommended when you’re looking to get the ultimate unboxing experience.

Source: PakFactory

A custom packaging insert is made specifically for your product, helping it stay in place to provide an elevated presentation while offering a high degree of shock protection, even against drops and rough handling.

Custom inserts most commonly come in;

• Paperboard
• Corrugated
• Molded pulp
• Foam
• Plastic

Is It Right For You? The Pros and Cons of Rigid Boxes

So now that we’ve finally covered all the available design choices, why should you choose this option? Well, besides its solid and protective construction, rigid packaging offers an elusive, luxurious and robust look and feel that is unmatched by most other packaging types.

Often paired with a custom insert, this packaging solution keeps products well-protected to withstand harsh handling. It is even made to be reusable and kept by the customer rather than just thrown away after unboxing a product.

With these benefits in mind, rigid packaging boxes build an embedded element to accompany your product, adding significant value to your brand. Customers will no longer view your product as just an individual item but rather consider the package and product as a set when your product is elegantly encased in a rigid box. 

It is human nature to enjoy gifts, and rigid gift boxes are currently the gold standard of gift-type packaging. But with any type of packaging option, there are bound to be drawbacks.

While this packaging option is excellent for small to medium product sizes, they can become surprisingly less resilient at extra-large sizes. They are more prone to ripped edges at larger sizes due to increased load on the outer layer of wrapping paper, so it is always recommended to use thicker paper with a laminated finish to increase durability at larger sizes.

But the biggest con for high-end, custom rigid boxes is their price. To be blunt, making one of these boxes is expensive.

The construction of these high-end packages is unlike any other packaging style. Similar to wrapping a gift, custom rigid boxes are made by precisely wrapping paper around solid boards. Each chipboard is individually glued together, and producing these boxes involves an extended process that can take 1-2 weeks longer than other packaging options.

Currently, most production processes for this type of packaging involve some degree of manual assembly and more detailed quality checks to inspect for defects and ensure quality standards are required, making it up to 3 times more costly than folding carton and corrugated packaging.

Source: PakFactory

And though the higher price can be readily justifiable to more prominent brands as luxury packaging adds tremendous amounts of perceived value to both the product and brand, we understand that many smaller companies are under budget constraints. For that reason, please check out our other article on how to create affordable luxury packaging and learn the many ways you can cut costs for rigid boxes and other options!

Rigid Box Solutions For Brands Across All Industries

With imagination comes courage, and with courage comes new and exciting ideas. Rigid packaging offers endless options for customization, personalization and luxury to fit any brand in any industry.

Don’t believe us? Check out some more cool rigid box ideas from different brands we’ve worked with!

Coca-Cola: The Taste of Celebration – Telescope Rigid Box with Custom Insert

Contender Brands: Combining Simplicity, Joy, and Laughter – Rolled-edge Rigid Tube Packaging with Custom Insert and Game Cards

Avec La Vie: Healing in a Package – Telescopic shoulder neck rigid box with game cards

Beda Beads: Inspiring the Next Generation of Creators – Magnetic Closure Rigid Box with Custom Insert

The post Rigid Box Packaging – The Master Guide first appeared on PakFactory Blog.

The post Rigid Box Packaging – The Master Guide appeared first on PakFactory Blog.

The adaptability to different product types, sizes, and use cases has all contributed to this growing trend that is even more significant in the food, pharmaceutical, and personal care industries. Due to the convenience of usage, storage, extended shelf life and sustainability, flexible packaging solutions have greatly benefited these industries by providing a versatile option preferred by both businesses and consumers. 

In fact, a study by Harris Poll found that 71% of respondents expressed an apparent inclination toward flexible packaging over rigid box counterparts. Of that percentage, 79% were knowledgeable about the packaging alternative and were willing to pay up to 14% more for this convenient and hygienic option.

So with the rapidly growing market share and business and consumer preference in mind, it is evident that this packaging solution will continue solidifying its position as a superior option across many industries.

Source: PakFactory

That being said, if you are considering using a flexible packaging solution for your product, you’ve come to the right place! In this article, we will cover everything you need to know about this excellent packaging option to ensure you have all the necessary knowledge to make this critical decision.

What is Flexible Packaging, and Why is it Better?

Before deep diving into the many small details that make this packaging option great, it is essential to establish a broader, foundational knowledge to build from. So the first question to always ask is, what exactly is it?

As the name suggests, flexible packaging is a versatile solution made from pliable packaging materials like plastics, paper, films, foils or a combination of all of them. It is any type of packaging capable of changing shape when filled or used, making it a preferred choice for businesses and consumers with its ability to remain lightweight, cost-effective, reduce carbon footprint, extend product shelf life, and take on endless customization.

Compared to traditional packaging types like rigid boxes, flexible packaging is more lightweight and cost-effective. The films and barriers that produce the pliable materials require fewer resources and energy to manufacture while offering a more cost-effective approach to shipping, warehousing, and logistics. Businesses gain the opportunity to save across the entire supply chain while maintaining a high-quality standard, but the benefits don’t end here.

The fewer resources and energy requirements to manufacture saves money and cuts the quantities of greenhouse gases produced compared to traditional packaging. Even during disposal, the efficient use of materials results in less overall waste sent to landfills, minimizing the negative environmental impact of this packaging option and making it an excellent step toward sustainability and a reduced carbon footprint.

Source: PakFactory

Flexible packaging solutions even offer an extended shelf life and increased protection against contaminants. According to ePac Flexibles, this packaging option creates a barrier against oxygen, moisture, light, and microorganisms, which can cause oxidation, spoilage, discoloration, and contamination. This increased protection benefits the product’s shelf life and reduces the risk of product waste created from spoilage.

Finally, endless customization and options for branding are available. The possibilities are truly limitless, from choosing vibrant colors and captivating graphics, incorporating your logo and brand messaging, or selecting the type of package you want with a wide range of options, such as spouted, flat, or stand-up pouch packages. By leveraging these customization options, you can create packaging that protects your products and is a powerful marketing tool, leaving a lasting impression on consumers. 

Browse our full catalog of flexible pouches here!

Key Considerations When Planning the Design of Your Flexible Package

Now with all the benefits of flexible packaging fresh in your mind, are you convinced to use this packaging solution for your products? If so, let’s look closely into the key considerations before beginning your planning.

Designing effective and successful packaging requires careful consideration of several vital factors. Packaging is the first point of contact between your product and the consumer, so creating a design that captures attention and communicates your brand’s value is crucial. Elements such as color, typography, and graphics are integral to conveying your desired message and attracting the target audience.

Source: PakFactory

Understanding your product’s requirements is also important for selecting the appropriate packaging materials and formats. Product freshness, shelf life, and transportation considerations are all crucial factors you must consider but do not exclude sustainability. Incorporating sustainability and eco-friendly practices are becoming increasingly important in today’s market as more consumers seek environmentally conscious businesses. And though many crucial factors like those mentioned above require careful consideration, you don’t have to do it alone.

Consulting packaging design and manufacturing experts is highly recommended, as they possess the expertise and industry knowledge to help you make informed decisions regarding materials, structural design, and user-friendly features. Conjunctively, you may look to the consumers too. By analyzing consumer behavior, conducting surveys, and studying market trends, brands can gain insights into consumer preferences which helps packaging designers make informed decisions regarding the visual aesthetics, functionality, and features of the packaging.

Successful packaging design is a collaborative effort to balance aesthetics, functionality, and sustainability to create a memorable, impactful solution. And with flexible packaging, finding this balance has never been easier.

Flexible packaging is adaptable and practical, enabling an enhanced user experience and adding value to your product through easy reusability, convenience and sustainability. It even allows creative design elements that captivate potential buyers with its pliable nature allowing for imaginative, innovative shapes, colors, and textures that make products stand out on the shelves. 

Even for branding, which is crucial in differentiating products in a competitive market, flexible packaging provides ample space to effectively use creative graphics, logos, and brand messages, ensuring that the packaging design aligns with your brand’s identity and establishes a strong visual connection with consumers.

But even when all of these creative branding and customization options are available for your experimentation, it is essential to remember that structure, protection, and functionality are equally, if not more, important considerations.

Source: PakFactory

The package should prioritize the protection of the product but maintain convenience, ensuring its freshness and integrity while catering to a user-friendly experience that all consumers want. You can do this by carefully selecting suitable materials and considering factors like barrier properties, puncture resistance, and shelf life. Striking the right balance between convenience and protection in your package’s design is critical to meeting consumer expectations and differentiating yourself from the competition.

So what materials should you use to find the balance? Professional packaging designers and manufacturers will help you find the best material for your product, but let’s look into some of the popular materials used in flexible packaging to better understand what’s available.

Selecting the Right Packaging Materials

The choice of materials significantly impacts the overall performance and suitability of any packaging solution, especially for flexible packages. Factors such as product compatibility, barrier properties, and sustainability considerations are pivotal in selecting the appropriate materials that complement and enhance your product.

Regarding flexible packaging materials, several options have gained popularity due to their performance and suitability for different industries:

• Bioplastics, such as plant-based bottles made from biodegradable plastics, effectively prevent air, grease, and oils from permeating the product, making them standard for flexible plastic packaging in the food and snack industry. 

• Polymer films, particularly plastics, dominate the market due to their flexibility and durability, making them widely used in the food industry. 

• Corrugated cardboard, though not strictly categorized as flexible packaging, offers protection against moisture and damage and serves as an excellent cushion during transportation. 

• Aluminum foil is an effective barrier against oils, moisture, and light while pliable enough to be shaped into various forms like trays and lids. 

• Kraft paper, known for its elasticity and strength, is commonly used for durable packaging of chemicals, food, and consumer goods. 

• UV protective films help preserve product quality by shielding against harmful UV radiation, commonly used in the food industry for storage and transportation.

And though the above materials are all popular and excellent choices for flexible packaging, in a bid for increased sustainability, let’s also look at a few alternate material choices that align with eco-conscious goals. 

Using fewer materials or incorporating Post-consumer recycled (PCR) materials is possible for brands looking for an eco-friendly initiative. Another avenue to consider is renewable resources, such as plant-based resins and paper, offering a greener alternative to plastic. Polylactic acid (PLA) film can also be incorporated, providing an industrially compostable option. 

Sustainable material options are crucial in reducing the environmental impact, so take note of these options! As more consumers demand eco-friendly initiatives from companies, you will only be limiting yourself if you do not carefully consider all avenues of possible materials in your packaging, including sustainable alternatives.

A circular, sustainable economy is crucial for eco-conscious practices as it minimizes waste and maximizes resource efficiency throughout the product lifecycle. Unlike the traditional linear economic system, a circular economy focuses on reducing waste and pollution, utilizing renewable energy and resources, promoting material circulation and recycling, and aligning supply chains with nature-centric principles. 

For flexible packaging, in particular, these practices ensure that it has a minimal environmental impact. Flexible packaging plays a crucial role in the circular economy by using fewer raw materials, facilitating easy recycling and reuse, and enabling composting for biodegradable packaging. By embracing the circular economy, businesses can significantly reduce the carbon footprint of packaging and contribute to a more sustainable future.

Printing Techniques and Graphic Design

But now that you’ve got a better understanding of the plethora of available materials at your disposal, both popular and sustainable, it’s time to dive into the possible printing techniques and graphic designs you can apply to them.

With the many different materials available and various forms of flexible packaging like stand-up pouches, you’ll be pleased to know that you have as many printing options too! You can choose from multiple printing and curing technologies to add colors, text, and graphics to your packaging design, like:

• Flexography is a popular method for pliable materials with excellent print quality and color vibrancy. It is capable of printing intricate designs and patterns on various flexible substrates. 

• Digital printing provides precise and detailed graphics with customizable elements. With digital printing, brands can create vibrant and eye-catching packaging while maintaining cost-efficiency for shorter print runs.

• Rotogravure printing is known for its exceptional image reproduction and is suitable for applications that require rich and detailed graphics.

By utilizing these advanced printing techniques and incorporating high-quality images, fonts, and colors that align with your product and brand identity, you can create visually appealing and impactful designs that effectively convey your brand’s message and resonate with your target audience.

Safety, Compliance and Quality for Flexible Packaging

So now that you’ve planned the packaging design, have chosen the materials and looked at the printing methods, what’s next? The next step is to meet the industry standards and regulations for this type of packaging. Quality control for flexible packaging involves various tests and measures to ensure its integrity and performance. These tests include:

• The Pressure Decay Test measures the package’s ability to hold pressure and detects any leaks or defects.

• The Instron Test evaluates the seal strength of the packaging, ensuring it can withstand the turbulence of handling and transportation without compromising integrity. 

• The Bell Jar Test assesses the barrier properties of the packaging materials, determining their effectiveness in protecting the contents from external factors such as moisture and oxygen.

Source: Unsplash

These quality control processes are necessary to provide manufacturers with valuable insights into the quality and performance of the flexible package. By conducting these tests, manufacturers can identify any weaknesses or deficiencies in the design or materials, allowing them to make necessary adjustments and improvements. Moreover, adhering to recognized industry standards ensures the package meets the required specifications and consistently delivers reliable performance and compliance.

But quality control is for more than just controlled environments. The global supply chain faces increasing challenges in ensuring product safety. Food recalls have increased, with microbial contamination and unsanitary handling significant contributors. Rigorous testing is necessary throughout the entire supply chain to protect consumers and minimize health risks.

Compliance with regulations and certifications across the board is crucial to ensure the health and safety of consumers by meeting stringent standards for material safety, hygiene, and product quality. Certifications such as FDA, CFIA, and EU compliance demonstrate adherence to specific regulatory frameworks and allow brands to provide assurance to consumers, build trust, and contribute to responsible and ethical packaging. 

Industry Insight: Nestle’s Sustainable Initiative with Flexible Packages

If you are still unsure whether to use flexible packaging for a safer convenient, and more sustainable alternative to traditional packaging, let’s look at a quick example of a big company, Nestle, and how they actively incorporate this type of packaging.

Source: Unsplash

Nestle has implemented a comprehensive sustainability initiative that embraces flexible packaging as a key product element. This initiative revolves around the three core principles of better packaging, less packaging, and better systems.

In pursuing better packaging, Nestle aims to reduce its reliance on virgin plastic by actively seeking alternatives and exploring innovative solutions. This includes piloting reuse and refill systems, increasing the utilization of paper and flexible packaging, and supporting the development of efficient collection, sorting, and recycling systems in the countries where the company operates.

To create a better system for packaging waste management, Nestle collaborates with partners globally to address the infrastructure challenges associated with collection, sorting, and recycling. Through joint projects and activities, Nestle seeks to model successful collection schemes and promote establishing well-functioning systems.

Through its dedication to sustainable packaging practices, Nestle actively contributes to the transition towards a circular economy, where resources are managed efficiently, waste is minimized, and environmental sustainability is prioritized.

Looking to The Future and Beyond for the Flexible Packaging Market

Flexible Packaging is relatively new. With this being said, innovation and evolution are constantly occurring, and this alternative solution to traditional packaging is only getting better and more advanced with time.

Innovations in smart packaging are beginning to coalesce and merge with flexible packaging. Advanced sensors and indicators can now monitor product condition, ensuring freshness and safety throughout the supply chain by detecting spoilage and filtering out harmful agents that might invade the package. And with the recent introduction of QR codes, RFID tags, and NFC, vital information is now provided to consumers, which helps prevent theft and counterfeits. Smart packaging solutions specifically designed for flexible packaging only improve product quality further, empower consumers with information, enhance brand relevance and ensure food safety.

Source: Unsplash

Flexible packaging is rapidly gaining popularity due to its convenience, lightweight nature and positive environmental impact. This is only further enhanced when combined with smart packaging and its advanced innovative technologies. Soon, this type of packaging will no longer be the alternative. It will become the standard across many industries with its versatility and ability to adapt to consumer preferences for sustainability and user-friendliness.

So if you want to start with a flexible packaging solution, discuss your options with one of our product specialists and get expert advice on the packaging solution that is right for you!

The post Flexible Packaging – The Master Guide first appeared on PakFactory Blog.

The post Flexible Packaging – The Master Guide appeared first on PakFactory Blog.

The flexographic printing press is a method that is considered to be the modern-day letterpress as it can print on large quantities of substrates including:

• Plastic
• Paper
• Metals 
• Films
• Cellophane 

Flexographic printing press technology is time efficient, cost effective and offers a versatile range of options. 

From food packaging to labels, flexo printing provides high print quality results without sacrificing your budget. 

Let’s delve deeper into the flexographic printing press process and how you can use this printing technology to your advantage.  

The Advancement of Flexo Printing

One of the most significant advancements in flexography is the integration of digital technology.

This technology has made the printing process more efficient, with faster turnaround times and higher levels of accuracy.

By using digital imaging technology, it is possible to produce high print quality images with vibrant colors and sharp detail.

This has opened up new possibilities for flexography, such as printing on a wider range of materials and producing more complex designs.

In addition to digital technology, sustainability improvements have also played a crucial role in the evolution of flexography.

Many printers are now using eco-friendly flexographic printing inks and solvent based inks, which have a lower impact on the environment.

These inks are made from natural ingredients and renewable resources and do not contain harmful chemicals that can harm the environment.

The Flexographic Printing Process

The major processes involved in flexographic printing include:

• Image preparation

• Flexible plate making

• Mounting

• Printing

• Finishing

The chosen material or substrate will be placed on a roll which will pass through a series of rotary flexible relief plates. 

A special roller feeds each flexible printing plate with one color of ink. 

Each color will require an individual flexible printing plate as each flexible plate works interchangeably to provide all the colors on the final printed product. 

The great thing about flexo printing is that you can incorporate special finishes within the process including:

• Embossing/debossing

• Die-cutting

• Foil stamping

• UV coating

These additional processes can be integrated with printing to get the job done in a single pass through. 

Flexographic inks have a low level of viscosity, and as a part of the process, they lie on the surface of substrates until they solidify.

While this may seem simple enough, flexographic printing is actually more complex as different types of flexographic printing options come into play.

Flexographic printing has changed rapidly over the years and has developed to deal with a variety of different printing options.

Some of the types of printing options include:

Traditional flexo: Uses doctor blades to remove excess ink and spread solvent based inks onto plates and ensure that color is evenly spread while in direct contact with a substrate.

Enhanced flexo: A refined version of traditional flexo, this process utilizes central impression cylinders to produce crisp images at a much greater level of quality. It is also more cost effective than traditional flexo!

The Advantages and Disadvantages of Flexographic Printing

Advantages of Flexographic Printing

• Prints absorbent & non-absorbent substrates: It is able to print images on plastics, brown papers, acetate films, corrugated boards, fabrics, cellophane, and it can effectively print brilliant continuous patterns at a high quality.

• Utilizes a wide variety of inks: It can apply water-based inks, UV curable inks, and solvent inks, all of which are incredibly fast-drying making it sustainable and time saving.

• The process is highly flexible: The process is capable of printing millions of impressions and can cater to a tremendous range of cylinder repeat lengths to accommodate customer specifications.

• Low cost & efficient: The process is also more cost-effective when compared to its competing methods as it leads to faster production due to its high-speed process and flexographic inks.

Disadvantages of Flexographic Printing

• Generic printing: Flexo printing cannot create meticulous artwork that other forms of printing are capable of such as offset printing.

• Costly equipment & materials: The cost of printing plates is high, as separate plates must be purchased for different colors. The cost of wrapping and distorting images is also exceptional.

• Lacks short-run capabilities: This type of printing is typically not viable for small quantities or sampling, unlike digital printing, since digital does not require a set up process. 

The Environmental Impact of Flexo Printing

Flexography printing has an impact on the environment, just like any other printing method.

The flexographic printing process requires significant energy consumption, generates waste in the form of unused ink, flexographic printing plates, and packaging materials, and uses chemicals that can be harmful to the environment and human health.

Water consumption is also a concern since the process requires a significant amount of water to clean a flexographic printing plate and equipment.

However, there are steps that can be taken to minimize the environmental impact of flexographic printing.

Eco-friendly flexographic printing inks and solvents can be used, waste reduction and recycling programs can be implemented, energy-efficient equipment and practices can be adopted, and water conservation practices can be put in place.

By taking these steps, flexography printers can reduce their environmental impact and contribute to a more sustainable printing industry.

Flexography vs Offset

Both flexographic printing and offset printing provide optimal results, and oftentimes you can’t tell the difference in the finished product. 

It’s important to understand the difference between these printing methods to ensure you are choosing the right technology for your project. 

The key differences between flexographic printing and offset printing include: 

• Flexography uses rotary flexible plates to print on a substrate, rather than printing indirectly through a series of offset plates. 

• Instead of finishes such as die-cutting, folding and lamination being applied after the offset printing process, flexography integrates special finishes and functions into a single pass through. 

• Offset printing is only capable of printing on smooth or flat surfaces, requiring additional processes for porous and absorbent materials for effective results. Whereas flexography is able to print onto almost any type of substrate.

• Integrating additional processes into a single pass through allows flexographic printing to provide significant economies of scale whereas offset printing can be extremely costly and takes more time.

Flexographic Printing and Packaging Design

We now have a broad spectrum of capabilities through flexography as discussed above.

Flexographic printing requires a range of design considerations, especially when it comes to labels and packaging. 

Your design and file preparation could affect the printing quality of your finished product. While this is true for all printing processes, it’s important to take these specifications into account when designing: 

Packaging materials

While flexographic printing accepts a wide range of substrates, it’s best to pick a non-porous material to ensure fast drying and curing times. 

Porous materials also affect the readability of text because the ink absorbs into the substrate. 

To clearly communicate information through your packaging, choose flexible and smooth packaging materials. 

Text and numbers 

Pick a reasonable font size to ensure information printed onto packaging materials, such as natural kraft, is easy to read.

For most materials, the minimum font size lies between 4 and 10 point type.

While this is quite a large size range, your font type also plays a role in choosing your font size.

Keep in mind; Sans serif fonts can show up smaller in some instances while serif font types should be slightly larger for legibility.

Read more on font types for custom packaging

Artwork designs

Minimalist designs with blocks of color are best as it requires minimal flexible rotary plates for quality results. 

More complex designs can get costly since each color requires an individual plate during the flexographic printing process. 

For complex designs, choose offset printing as it ends up being more cost effective per unit of packaging. 

Looking to learn more about printing options for your product packaging? Get in contact with our product specialists today!

The post What is Flexographic Printing? first appeared on PakFactory Blog.

The post What is Flexographic Printing? appeared first on PakFactory Blog.

What does it mean to emboss paper? What about deboss? If you have these questions, you’ve come to the right place!

Embossing paper and debossing paper are like two sides of the same coin.

They are popular finishing processes that press images, designs, and texts into paper and other materials but are different in that they are opposites.

Embossing paper creates raised silhouettes of your artwork design on a piece of material while debossing leaves a deep impression.

Both processes have a wide range of applications, including:

• Brochures
• Postcards
• Business cards
• Letterheads
• Certificates
• Folders
• Packaging (of course)

Paper embossing creates visual complexity by adding a new dimension to your brand messages and graphics by enhancing your logo, text or artwork designs.

The Benefits of Embossing and Debossing

Embossing and debossing are two popular design techniques used in packaging that can provide a variety of benefits.

Firstly, these techniques add a sense of sophistication and luxury to the packaging, making it stand out on the shelves and catch the eye of potential customers through an embossed image or text.

Secondly, they create a tactile experience for customers, making the product more memorable and appealing.

In addition, embossing and debossing can highlight essential information, such as branding or product features, which can help the customer make informed purchasing decisions.

These techniques are also highly durable, making them resistant to wear and tear, ensuring that the packaging maintains its visual appeal over time.

Overall, embossing and debossing are essential to design strategies that can provide significant advantages to any packaging design project.

Die Types and Styles of Embossing/Debossing

Paper embossing can incorporate several die types and styles to achieve unique effects.

But before we get into that, let us briefly look at the three most common metals used for embossing and debossing dies: magnesium, copper and brass.

Magnesium is only usable for single-level die types and is the cheapest but softest metal. This metal is susceptible to quick wear and damage should it jam on the stamping press.

Copper, like magnesium, is only used for single-level dies but is sturdier and more expensive.

Brass is required for multi-level and sculpted die types. It is the hardest metal of the common dies and will last very long, but it is two to three times more expensive than copper.

What Are The Die Types?

Now that you know the common metal plates used for dies, we can dive into the different die types to emboss paper.

Detailed dies can create more intricacy and depth to take the visual interest of your design to the next level, but depending on your needs, many options are available to you:

Single-Level – As the name suggests, this die type changes the material’s service at one level. It is the most common and cheapest method.

Multi level Emboss– A die type that features several distinct levels.

Bevel-edge – Similar to a single-level die, but with a 30 to 60-degree angle on the design’s edge. Deeper dies need a bevelled edge to prevent cutting the material.

Chisel – Frequently used for debossing, this die has a distinct “roof” shape or v-shape.

Textured – A single-level die with etched texture. This die type works best with artwork that does not require details to look refined.

Rounded – A die type that produces rounded corners commonly used for logos and typographic elements.

Sculptured – The most expensive die type. It requires a hand-made custom sculpt from a provided reference for the stamped image or embossed pattern.

Embossed Paper and Debossed Paper Styles

Not only are there many different die options, but there are also several styles of embossing/debossing to choose from too! These styles include:

Blind Embossing – The blind emboss style does not use ink or foil stamping. It provides a distinct and clean design that is best for subtle looks on embossed paper.

Registered Emboss – This style uses ink, foil stamping or another embossed effect to create more dimension and a shiny or polished appearance to your design.

 Combination Embossing – This style incorporates foil stamping and blind embossing for a. It is often used to highlight key details of a design, such as logos, slogans, or graphics. The design is embossed and lined with foil to create an impactful 3D design.

The Embossing and Debossing Process

With the styles and types of die out of the way, it’s time to look at the machining process.

Thankfully, using an embossing machine is reasonably straightforward.

A male die with the embossed image is placed underneath the material, while another female die is positioned above it.

The machine then presses the male and female die together to stamp the design onto your material for an embossed image.

Why is Embossing and Debossing Used?

This technique works exceptionally well for heavier stocks like corrugated boxes and rigid setup boxes.

And as mentioned earlier, adding foil stamping to the embossing process is also possible and enhances the visual intensity of the printed piece through heat embossing.

Foils such as gold and silver are common choices for heat embossing, but solid colors work just as well and can enhance your product’s visual quotient.

Why Use Embossing and Debossing?

Finally, you may wonder why you should use the embossing process on your product. What is embossing/debossing’s benefit to your brand?

Well, it creates a memorable experience for your customers. The details literally pop out to customers and command their attention.

Embossing/debossing differentiates your brand and provides an excellent ROI, as it can significantly increase your product’s visual impression and perceived value without costing too much. 

Overall, using finishing techniques like embossing or debossing is an easy way to elevate your branding and progress your packaging design to the next level!

The post What is Embossing and Debossing in Packaging first appeared on PakFactory Blog.

The post What is Embossing and Debossing in Packaging appeared first on PakFactory Blog.