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by Grace Tylor – January 5, 2021
Product packaging has played an important role in the consumer decision-making process during a retail or e-commerce buying experience. More than 52% of online consumers would most likely return to a business if they received their product in high-quality packaging, and 74% of consumers will most likely share a photo of product packaging in their social media. As you can see, an effective product packaging design can create tons of leverage for your business.
Bringing new packaging ideas to life, however, can be a daunting task, and there are so many factors to take into consideration. For your convenience, we created a comprehensive guide to take you through every step of the process in the simplest way.
Before diving into the packaging process, there are four crucial questions you must answer to ensure you choose the best solution for your product and business needs.
1. What type of product is it?
Understanding the type of product you are packaging is fundamental. The packaging requirements will vary significantly based on the product’s size, shape, and weight. For instance, a delicate and fragile item like glassware or electronics will necessitate packaging that offers substantial protection, including structural integrity and cushioning materials to prevent damage during transit. Conversely, a more durable item might only require basic protection. Identifying these specific needs will guide you in selecting the appropriate materials and design for your packaging.
2. How many units are needed?
Determining the number of units required is another vital consideration. Whether you need 100, 500, 1,000, or even 10,000 units, knowing this number is essential as it directly impacts your overall costs and logistics. Bulk orders typically result in lower per-unit costs due to economies of scale, but they also require a larger upfront investment. Understanding your exact needs helps in budgeting and planning your production schedule effectively.
3. What is your budget?
Budgeting for packaging involves more than just the cost of the boxes or containers themselves. You need to account for the total expenses, which include packaging materials, printing, shipping, and any additional fillers or cushioning materials needed to protect your product. It’s essential to have a clear budget in mind to prevent overspending. Fortunately, there are various ways to minimize costs without compromising on quality, such as choosing cost-effective materials or negotiating better rates with suppliers.
4. What is your marketing and business timeline?
Your packaging timeline should align with your overall business and marketing schedule. Consider your product launch dates, current inventory levels, and any promotional activities that might influence when you need your packaging. It’s crucial to plan ahead to avoid delays that could disrupt your business operations. Having a clear timeline ensures that your packaging is ready when you need it, supporting a smooth product launch or restock.
By thoroughly answering these questions, you can make informed decisions about your packaging needs, ensuring that your products are well-protected, cost-effective, and ready for market on time.
Box dimensions are a critical aspect of any packaging solution. The dimensions of a box significantly impact the required materials, the cost of production, and the cost of shipping.
Key Dimensions: Length, Width, and Depth
Boxes are measured in three main dimensions: length, width, and depth. It’s important to note that these measurements are always taken from the inside of the box, not the outside. This ensures that the internal space accurately reflects the capacity needed for your product.
1. Length is the longest side of the box.
2. Width is the shorter side of the box’s base.
3. Depth (or height) is the distance from the top to the bottom of the box when it is sitting in its natural orientation.
Impact on Materials and Costs
Accurate dimensions are crucial because they determine the amount of material required to produce each box. Miscalculations can lead to either a surplus or a shortage of materials, both of which can be costly. Additionally, precise dimensions are necessary to optimize the cost of production. Overly large boxes will not only use more material but may also incur higher shipping costs due to increased weight and volume.
Accuracy in Measurement
While measuring your box might seem like a simple task, the accuracy of this step is paramount. Incorrect measurements can disrupt the entire packaging process, leading to wasted materials, increased costs, and delays.
To ensure accuracy:
1. Use a reliable measuring tool, such as a ruler or tape measure.
2. Measure each dimension from the inside of the box.
3. Double-check your measurements to avoid errors.
Accurately determining the box dimensions from the beginning will ensure a smooth and efficient packaging process. This foundational step will help you avoid unnecessary complications and ensure your product is well-protected and cost-effectively packaged.
There are various stocks offered in the custom packaging business but we offer four types of stock to our customers.
When designing packaging for your product, it’s essential to consider its intended use—whether for retail or e-commerce—as well as the dimension size and structure of the box. One of the critical factors in ensuring your products are held safely is selecting the appropriate flute type.
The thickness of the flute determines the durability of the packaging, with different types ranging from F-flute (the thinnest) to B/C flute (the thickest).
Understanding Flute Types:
F-Flute: The thinnest option, F-flute is commonly used for lightweight products and provides a smooth surface ideal for high-quality printing. It’s often chosen for retail packaging where the visual appeal is important, but the packaging does not need to withstand significant pressure or impact.
E-Flute: Slightly thicker than F-flute, E-flute offers a good balance between strength and printability. It is used for a variety of retail packaging applications and is suitable for products that require a bit more protection without sacrificing aesthetics.
B-Flute: This is a versatile option that provides excellent cushioning and crush resistance. B-flute is commonly used for heavier items and can be a good choice for both retail and e-commerce packaging, especially for products that need to endure shipping and handling.
C-Flute: Thicker than B-flute, C-flute offers even greater cushioning and is highly durable. It is often used for larger or heavier products that need extra protection. C-flute is suitable for e-commerce packaging where the product might experience rough handling during transit.
B/C Flute: This double-wall option combines the strength of B and C flutes, offering maximum durability and protection. It is ideal for extremely heavy or fragile items and is commonly used in e-commerce packaging to ensure the safe delivery of products.
Selecting the Right Flute:
To determine the appropriate flute for your packaging, consider the following factors:
Product Use: Retail packaging often focuses on visual appeal and may prioritize thinner flutes like F or E for better print quality. E-commerce packaging, on the other hand, requires sturdier options like B, C, or B/C flutes to withstand shipping and handling.
Dimension Size: Larger boxes may require thicker flutes to maintain structural integrity and prevent collapse or damage during transit.
Structure: The design and structure of the box can influence the required flute thickness. Boxes with intricate designs or multiple compartments may need additional support provided by thicker flutes.
By carefully evaluating these factors, you can choose the right flute to ensure your products are securely packaged, whether they are displayed on a retail shelf or shipped directly to consumers. This decision will enhance the durability and effectiveness of your packaging, ultimately protecting your products and maintaining customer satisfaction.
Card stocks are available in a range of weights, typically measured in grams per square meter (GSM), such as 350GSM, 420GSM, and 470GSM, or even higher. They are commonly used for various applications that demand more durability than standard paper can provide.
Key Applications of Card Stocks:
Retail Boxes: Used for packaging retail products where sturdiness and a premium appearance are essential.
Business Cards and Postcards: Ideal for creating durable and professional-looking business cards and promotional postcards.
Playing Cards: Used to manufacture playing cards due to their thickness and resilience.
Catalog Covers: Provide robust covers for catalogs and brochures, ensuring longevity and protection.
Scrapbooking: Preferred for creating scrapbook pages and covers that need to withstand frequent handling.
Surface Finishes:
Smooth: Most card stocks have a smooth surface, suitable for crisp printing and vibrant colors.
Textured: Some varieties offer a textured surface, adding a tactile dimension to printed materials.
Glossy or Matte: Available in glossy finishes for enhanced color vibrancy and matte finishes for a more subdued and elegant look.
Card stocks are versatile materials that combine durability with aesthetic appeal, making them suitable for a wide range of creative and commercial applications. Their ability to handle printing, cutting, and folding processes effectively makes them a popular choice among designers, printers, and businesses looking to elevate their printed materials.
Kraft stock is a robust and environmentally friendly material widely used for packaging purposes. It is available in various thicknesses, typically measured in grams per square meter (GSM), such as 350GSM, 450GSM, and 500GSM, or higher, to accommodate different packaging needs.
Key Features of Kraft Stock:
Durability: Known for its strength and resilience, kraft stock provides reliable protection for packaged goods, making it suitable for both retail and industrial applications.
Eco-Friendly: Made from natural fibers, kraft stock is biodegradable and recyclable, aligning with sustainability goals in packaging.
Natural Appearance: Its characteristic brown color lends a rustic and organic look to packaging, adding aesthetic appeal, especially in eco-conscious branding.
Versatility: Kraft stock is used for a wide range of packaging solutions, including retail boxes, shipping boxes, food packaging, and heavy-duty industrial applications.
Printing and Customization: While typically used in its natural state, kraft stock can also be printed on or coated to achieve specific finishes or designs, enhancing its visual appeal and functionality.
Overall, kraft stock combines strength, versatility, and environmental sustainability, making it a popular choice among businesses seeking durable and eco-friendly packaging solutions. Its natural charm and robust performance make it well-suited for various packaging needs across different industries.
After determining what type of product packaging is best for your business, you can determine what type of printing to go for. To break it down, these are the three printing options and what type of material they’re compatible with:
Offset Printing uses ink instead of toner (digital printing), resulting in a richer, clearer and more superior image quality—ultimately the highest quality printing option.
It is typically used for mass production, as it can get too expensive for most low-volume projects because it requires printing plates and additional setup fees. Another perk of using offset printing is the ability to apply special processes. It is available for all three types of box materials and is able to produce the highest quality print.
Digital Printing is just like how your home office laser or inkjet printer works. It offers quicker turnaround times and makes low-volume jobs affordable without any setup fees.
The only downside is that they can’t quite match the color fidelity and material flexibility that offset printing offers. It is available with folding cartons and corrugated boxes.
It is typically used for mass production, as it can get too expensive for most low-volume projects because it requires printing plates and additional setup fees. Another perk of using offset printing is the ability to apply special processes. It is available for all three types of box materials and is able to produce the highest quality print.
Flexography Printing is considered to be the modern-day letterpress and can withstand large quantities of packaging products like offset printing.
It is a form of industrial printing that is best for simple structures and printing one or two colors.
The colors aren’t as vibrant and crisp as the other two options, but this format of printing is inexpensive, it doesn’t require a lot of attention to detail, and can be produced at a very high speed.
If you are looking to enhance and add a more impact look & feel to your packaging, you can opt for special processes to create a more eye-catching unboxing experience.
Foil stamping is a decorative technique that elevates the look and feel of your packaging by using heat and pressure to apply a metallic or colored foil to various surfaces. It’s a popular choice for adding logos, lettering, and other designs to packaging, invitations, stationery, and more.
Here’s what makes foil stamping so versatile:
Variety of Foils: Choose from classic metallic finishes like gold, silver, and copper, or opt for a more modern touch with matte or gloss effects.
Eye-catching Effects: Take your packaging to the next level with holographic foils that shimmer with a rainbow-like sheen. Special effect foils can also add a touch of pearlescence, patterns, or other unique textures.
Simple Yet Effective Process: While it requires specialized equipment, foil stamping itself is a relatively straightforward process. A heated die with your design is pressed onto the material with the foil. Heat and pressure activate an adhesive on the back of the foil, causing it to bond with the surface. Excess foil is then removed, leaving behind your design in stunning detail.
Benefits: Foil stamping offers a cost-effective way to add a touch of luxury, elegance, or attention-grabbing detail to your packaging or other printed materials.
While UV coating offers a uniform layer of protection and shine to your entire packaging, spot UV coating takes a more targeted approach. It’s a technique where a clear, protective coating is applied only to specific areas of the packaging design, creating a visually striking contrast and a unique tactile experience.
Here’s a deeper dive into spot UV coating:
Targeted Enhancement: Unlike full UV coating, spot UV allows you to highlight specific design elements like logos, text, or graphics. This creates a focal point, drawing the viewer’s eye to the most important information on your packaging.
Tactile Contrast: Spot UV coating creates a raised, glossy effect on the targeted areas. This adds a layer of dimension and texture, making the packaging more engaging to hold and interact with.
Multiple Applications: Consider using spot UV for:
1. Highlighting your logo or brand name.
2. Making text or graphics pop with a glossy finish.
3. Creating subtle patterns or borders.
4. Adding a touch of elegance to specific design elements.
Blind Spot UV: This is a special variation where the UV coating is applied to a specific area, but a matte finish is used instead of the usual gloss. This creates a subtle textural difference that can be visually interesting without being overly flashy.
Benefits of Spot UV Coating:
Enhanced Visual Appeal: Draw attention to key elements and create a more dynamic and visually engaging packaging design.
Luxury Touch: The glossy finish and raised texture add a touch of sophistication and quality to your packaging.
Tactile Experience: The contrasting textures create a unique sensory experience that makes your packaging more memorable.
Versatility: Spot UV can be used in various ways to complement your overall design concept.
By using spot UV coating strategically, you can elevate the look and feel of your packaging, making it stand out on the shelf and grab the attention of potential customers.
Embossing is a decorative technique that adds a touch of sophistication and dimension to your packaging. It involves creating a raised design on the surface of the material, typically paper or cardboard, by pressing it from the back with a mold or die. This process creates a three-dimensional effect that enhances the visual and tactile appeal of your packaging.
Here’s a closer look at embossing:
The Process: A metal die with the desired design (logos, text, patterns) is used to press the material from the backside. This creates a raised impression on the front surface, while the back of the material remains relatively flat.
Design Considerations: Embossing works best with bold, simple designs. Fine details, small fonts, or intricate patterns can be difficult to achieve clearly and may lose definition during the process. It’s recommended to maintain a minimum thickness for raised elements to ensure durability.
Applications: Embossing is a versatile technique that can be used for various purposes:
Highlighting Logos and Text: Emboss your logo or brand name to create a lasting impression and enhance brand recognition.
Adding Texture and Dimension: Elevate your packaging design by embossing patterns, borders, or other decorative elements. This creates a visually interesting and tactile experience.
Creating Focal Points: Draw attention to specific areas of your packaging, such as important information or product features.
Benefits of Embossing:
Enhanced Visual Appeal: The raised elements add depth and dimension, making your packaging stand out on shelves and grab attention.
Luxury Touch: Embossing creates a sophisticated and high-quality look that elevates the perceived value of your product.
Tactile Engagement: The raised texture invites customers to interact with the packaging, creating a more memorable experience.
Versatility: Embossing can be used for logos, text, patterns, or borders, offering design flexibility.
By incorporating embossing strategically, you can transform your packaging from ordinary to extraordinary. It adds a touch of elegance, texture, and visual interest, making a lasting impression on your customers.
Debossing, often considered the opposite of embossing, is a decorative technique that creates a recessed design on the surface of your packaging. It involves pressing the material (typically paper or cardboard) from the front using a mold or die. This process creates a depressed impression, adding a subtle elegance and a unique textural element to your packaging.
Here’s a deeper look at debossing:
The Process: Similar to embossing, a metal die with the desired design is used. However, in debossing, pressure is applied from the front of the material, pushing it inwards and creating a sunken impression.
Design Considerations: Debossing works best with bold, simple designs. Fine details or intricate patterns may be difficult to achieve clearly and might lose definition. Since the design is recessed, consider elements that will be visually appealing with contrasting shadows and depth.
Applications: Debossing offers a sophisticated and understated way to enhance your packaging design:
Highlighting Logos and Text: Deboss your logo or brand name to create a subtle yet elegant impression that leaves a lasting brand memory.
Adding Texture and Dimension: Incorporate debossed patterns, borders, or other design elements to create a visually interesting and tactile experience. The contrast between the raised background and the debossed elements adds depth and texture.
Creating Focal Points: Draw attention to important information or product features by using debossing to create a subtle yet effective highlight.
Benefits of Debossing:
Sophisticated Look: Debossing creates a subtle elegance and a high-quality feel, elevating the perceived value of your product.
Textural Contrast: The recessed design creates a unique tactile experience that invites customers to interact with the packaging, making it more memorable.
Versatility: Debossing can be used for logos, text, patterns, or borders, offering design flexibility. It complements other decorative techniques like foil stamping or spot UV coating for a truly unique look.
By strategically incorporating debossing into your packaging design, you can add a touch of sophistication and subtle texture. It creates a visually interesting element that stands out without being overly flashy, leaving a lasting impression on your customers.
The mockup stage is a crucial step in the packaging design process. It allows you to visualize your design choices in a physical form before committing to full production. Finalizing the mockup ensures you’re happy with every detail and eliminates any surprises down the line.
Here’s a breakdown of the key steps involved in finalizing a packaging mockup:
Review and Refine:
Meticulous Inspection: Carefully examine the mockup for any inconsistencies, errors, or misalignments in text, logos, or graphics. Ensure all design elements are positioned correctly and adhere to your initial vision.
Color Accuracy: Verify that the colors on the mockup accurately represent your desired palette. Color variations can occur during printing, so it’s important to address any discrepancies before finalizing.
Material Suitability: Assess whether the chosen material for your packaging complements the overall design and functionality. Consider factors like durability, printability, and suitability for your product.
Feedback and Iteration:
Gather Feedback: Share the mockup with stakeholders, colleagues, or even a target audience (if possible) to gather feedback. Consider their comments on design elements, clarity of information, and overall brand representation.
Incorporate Refinements: Based on the feedback received, make necessary adjustments to the design. This could involve tweaking colors, fonts, layouts, or even exploring alternative materials.
Final Approval:
Once Satisfied: When you’re confident that the mockup perfectly reflects your vision and addresses all concerns, it’s time for final approval. This typically involves a sign-off from key decision-makers before proceeding to production.
Additional Tips for Finalizing Mockups:
Request Multiple Revisions: Don’t hesitate to request multiple revisions to ensure the mockup is exactly what you envisioned. Most design companies offer revision cycles within their services.
Consider Prototyping: For complex packaging designs, consider creating a prototype alongside the mockup. This allows for a more realistic assessment of functionality and user interaction.
Maintain Clear Communication: Throughout the process, maintain clear communication with the designer or printing company. Discuss your expectations, concerns, and any necessary changes promptly.
By following these steps and investing time in finalizing the mockup, you can ensure your packaging design is flawless and effectively represents your brand. It’s a crucial step that minimizes the risk of errors and paves the way for stunning and functional packaging that stands out.
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