How are customized boxes made?

Although bespoke boxes can be made from a number of materials, the following two are the most typical for this type of packaging:

SBS (solid bleached sulfate) paperboard: This whiteboard is constructed of virgin fiber. It is available in both coated and uncoated forms. Furthermore, it is generally flat and light, making it excellent for printing. Cutting, folding, embossing, and hot-foil stamping are all straightforward. This material is suitable for high-end packaging in pharmaceuticals, retail, and other sectors.

Corrugated board is a type of paperboard that has had the centre laminated with fluted paper. The fluted paper provides padding to the box, safeguarding the primary object. You may choose between a single-wall and a double-wall structure depending on the fragility of your goods. Corrugated box kraft may be found here.

Now that you're aware of the materials used, let's get started on creating unique packaging boxes.

Design and graphics

You must first give the design for your custom-printed boxes before the production process can begin. You are the one who knows what you want to show your clients or what they are interested in. Customers may build designs using Packlane's custom design configurator based on the colors, sizes, and graphic components they want.

Designers recommend choosing larger or bolder typefaces for readable printing. Furthermore, this ensures that tiny components, such as serif typefaces, are not lost while printing.

The following stage is printing. Printing processes for custom boxes include digital printing, flexographic printing, and litho laminating. You can choose your favorite printing method based on your unique company needs.

Relief printing (also known as flexographic printing)

This is the most common corrugated box printing method. A large rotating cylinder is connected to a flexible printing plate. The plate artwork is printed on the board as it passes through the machine.

This method is ideal for edge-to-edge printing, flood coating, and custom text designs. It's also suitable for one- or two-color line art.

Flexographic printing is not recommended for designs with complicated graphics and a high number of colors. This might be pricey because to the amount of printing plates required for the colors.

One of the most serious drawbacks of flexo printing is the "minimum dot." On paperboard, little halftone dots on flexographic plates comprised of a thick, flexible polymer composition cannot be properly reproduced. These dots print larger than what is on the plate, a phenomenon known as "dot gain." As a result, a limit exists: the minimal dot. As a result, the tone range that may be replicated is restricted.

Lithographic printing (sometimes known as offset printing or lamination)

Litho lamination is the process of putting offset lithographic printing onto corrugated board. After lamination, the box will be trimmed to the final proportions by the manufacturer.

This approach is great for producing very detailed, high-resolution graphics. It offers several options and diversity in terms of images, colors, and other finishes. Unfortunately, litho-lamination is the most expensive printing method, thus suppliers suggest it for projects requiring thousands of copies.

Printing on Demand

Digital printing is a feasible alternative to older technologies such as lithography and flexography since it is quicker. Many physical stages of traditional printing are avoided, such as developing films and color proofs, stripping the components together, and producing plates. It's also suitable for short to medium print runs. The prints may be applied directly to the corrugated board, eliminating the need to mix multiple ink colors. Please contact us if you require some packaging boxes.