How are custom boxes created?

Although custom boxes can be produced from a variety of materials, these two are the most common choices for this kind of packaging:

Paperboard SBS (solid bleached sulfate): This whiteboard is made of virgin fiber. It is offered both coated and uncoated. Additionally, it is usually flat and light, which makes it ideal for printing. Cutting, folding, embossing, and hot-foil stamping are simple. This substance is appropriate for luxury packaging used in pharmaceuticals, retail, and other industries.

Corrugated board: This is a paperboard that has been laminated in the middle using fluted paper. The fluted paper gives the box a cushioning effect, protecting the main item. Depending on how fragile your product is, you can pick between a single-wall or double-wall construction. Click here for corrugated box kraft.

Let's get started on the making of custom packaging boxes now that you are aware of the materials that are employed.

Graphics and Design

Before the manufacturing process can start, you must first supply the design for your custom-printed boxes. You are the one who knows what you want to display to your clients or what interests them. Customers can create designs using the custom design configurator that Packlane offers, depending on the colors, sizes, and graphic components they choose.

For legible prints, designers advise using bigger or bolder typefaces. Additionally, this guarantees that minor elements, like serif fonts, are not lost when printing.

Printing

Printing is the next step. Custom boxes are printed using a variety of techniques, including digital printing, flexographic printing, and litho laminating. You can select your preferred form of printing based on your specific business requirements.

Flexographic printing (also known as relief printing)

This is the most typical corrugated box printing process. A big revolving cylinder is linked to a flexible printing plate. As the board is run through the machine, the plate artwork is printed on it.

This technique is perfect for edge-to-edge printing, flood coating, and unique text designs. It's also a good option for one- or two-color line art.

Flexographic printing is not suggested for designs that contain complex graphics and a large number of colors. Because of the number of printing plates necessary for the colors, this can be costly.

One of the most significant disadvantages of flexo printing is the "minimum dot." Small halftone dots on flexographic plates made of a thick, flexible polymer composition cannot be reproduced reliably on paperboard. These dots print larger than what is on the plate, which is referred to as "dot gain." As a result, there is a limit: the minimum dot. As a practical result, the tonal range that may be reproduced is limited.

Lithographic Printing (Offset Printing or Litho Lamination)

The method of mounting offset lithographic printing onto a corrugated board is known as litho lamination. The manufacturer will cut the box to the final dimensions after lamination.

This method is ideal for creating highly detailed and high-resolution visuals. It provides numerous possibilities and versatility in terms of pictures, colors, and other finishes. Unfortunately, litho-lamination is the most expensive printing technology, which is why vendors recommend it for projects with thousands of copies.

Digital Printing

Because it is faster than traditional methods such as lithography and flexography, digital printing is a viable alternative. Many physical phases of traditional printing, such as developing films and color proofs, stripping the pieces together, and making plates, are eliminated. It is also appropriate for short to medium print runs. The prints can be put straight to the corrugated board, with no need to mix different ink colors. If you require some packaging boxes, please contact us.