Chapter 3- Packaging Printing Options

– Suitable printing makes your brand visible!

Printing is so essential to custom packaging. There are three major printing options in the world, and they are called Offset printing, flexo printing, and screen printing. We can talk about it in 2 ways: printing artwork design and printing machine.

Printing Artwork Design

Whether your company has an in-house designer or you hire someone to finalize your design, it’s important to stay in close communication with your designer. Your ideas will impact the final design work, so we suggest that you create a draft first. The artwork design can apply CMYK color and Pantone color if needed. Let’s go through the steps:

Determine the size of your packaging.
Identify the printing elements and their location on the packaging.
Leave enough space for bleeding once printing is complete.
Obtain a packaging template to load the artwork design onto.
Packaging companies usually require Adobe Illustrator files or high-resolution PDF files. Don’t forget to create outlines if you send an AI file, insert the images into the AI file, and send it together.
Ensure that your font is clear and not too thin, as it may be difficult to read.
Request that your packaging manufacturer provide a mock-up picture before proceeding with a sample or bulk order.
See this packaging design guidance if you still have questions.

Once you’ve completed these steps, you can discuss the next steps with your packaging supplier.

Printing Machine

It’s essential to learn your packaging manufacturer’s ability to do the printing. That isn’t good when you make lots of effort in printing artwork design, but get to know your packaging manufacturer can’t proceed with this because their printing machine is old and does not support many colors.

Also, you need to know the maximum size of their printing machine support; oversized artwork may be rejected or need glue-joint. Below let’s talk this for the different machines.

Offset Printing Machine

Komori and Heidelberg offset machines are the most advanced in the world. They can support as much as eight colors one time (CMYK + 4 Pantone color). The maximum size can be 1220*1620mm. There are smaller sizes with lower printing costs:

520*720mm/720*1020mm/1000*1400mm, these are some small printing machines’ printing size ability.

Offset Printing Machine

Flexo Printing Machine

Beiren Group is the biggest flexo printing machine manufacturer in the world. The limit of width is 2300mm, and no limits on the length of the cardboard. It can be printed as many as six colors, some advance machine generates printing and cutting into a single flexo printing machine. It means that after printing, the box is also auto cut by the rest part of the machine, and it only supports slotted cartons so far. So you do not need to worry about the size of your box. Just talk with your supplier about color printing quality control.

Flexo Printing Machine

Screen Printing

Screen printing is like flexo printing, but it is not printed directly on boxes but through a screen template. The customers become more and more interested in the other two printing options, so screen printing is not the same popular as before. The screen printing machine is cheap, and it’s able to do UV at the same time.

Screen Printing Machine

Can Printing Options To Be Applied Onto Inside and Outside of The Box?

Yes, Offset printing, flexo printing, and screen printing can all be used for double-sided printing options. Here’s how it works:

Double-Sided Offset Printing: Corrugated board cannot be printed with an offset printing machine directly. Instead, it needs to be laminated with printed paperboard (such as CCNB paper, ivory paperboard, specialty paper, etc.). Once the outside printing is finished, laminate another printed cardboard on the inside of the box. If you are using a paperboard box instead of corrugated board, you can print two sides directly without lamination.

Double-Sided Flexo Printing: Corrugated board can be printed directly onto the cardboard. Simply repeat the process again, and a double-sided flexo-printed box will be created.

Double-Sided Screen Printing: The process is the same as flexo printing. If you have different designs for the inside and outside, you’ll need to create two printing plates and apply them accordingly.

With these printing options, you can achieve double-sided printing on your packaging.

What Are The Common Problems While Printing Process?

Printing is an essential part of the packaging process, but it can come with its own set of challenges. Here are some common problems that may arise during the printing process and how to solve them:

Real printing color does not match the artwork design: This is often caused by mistakes made during the printing process or by using an unprofessional printing machine. To address this issue, it’s best to communicate with your packaging supplier and ensure that your artwork is designed correctly.
Printing does not fit the box after the die-cut process: This issue can be caused by errors in the size of the design artwork, incorrect sizing of the die-cut plate, or mistakes made during the cutting process. It’s important to confirm your design before printing and discuss any concerns with your supplier.
Printing appears dull or matte instead of shiny: This is often the result of selecting the wrong finish, such as matte instead of glossy. It’s important to educate yourself on the different finishes available and select the right one for your needs. Learn more on this page.
Icons, emojis, or logos are not in the correct position as indicated in the artwork: This is usually due to an error made by the printing worker. They need to take care when handling the materials and ensure that each element stays in place.
Printed paper pigment appears blurry: This can happen when the printing finish method is not properly applied to protect the pigments after printing. Additionally, if the printing factory stacks the printed paper before it’s completely dry, this can cause smudging. Experienced printing factories should have a dry-house to finish this process, and the problem can be avoided.

How To Avoid Such Problems?
You’d better request several proofs or samples before mass production, no matter it’s digitally printed or bulk machine printed. Just see if the printing layer fits the box layout. If you are confident in your supplier, this step can be left out.

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