
PACKAGING 101
the basics

Types of Printing

How to measure a box
Inside or Outside Dimensions?
When you purchase and measure a box, shipping boxes are measured using the inside dimensions. This is done so that you know that your products will fit properly.
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Measure the length of the box first. This is the long side of the box on the side of the longest flap.
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Next, turn the box 90 degrees and measure the width, which is the side with the shorter flap.
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Last, measure the height of the package. This will be measured with the flaps closed, from top to bottom.
What are Dielines?
What are Proofs?
this section talks about the dieline and artwork process of packaging and display development.
Note - there are soft proofs (typically a digital PDF) and a hard proof (a large printed sheet of what is going to be printed. Its usually full size and used to print and copy, not color).
THE GLOSSARY
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Box Blank — A flat corrugated piece cut and scored, ready to be joined with other pieces to make a box.
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Box Style — A category that can be used as a helpful descriptor regardless of box size or construction.
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Carton — Any box style that can fold and ship flat, used mostly to house retail goods.
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Color Mockup — A full-color rendering of a given product’s packaging, created for promotional purposes. Color mockups enable the customer or seller to inspect and perfect every inch of the package design before it’s sent out.
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Co-Packer — A company specifically hired to manufacture and package products for a business partner.
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Corrugated — An industry term for cardboard boxes.
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Corrugated Box Dimension
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Dimensions refer to the interior of a box - length x width x height
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Length being the longest side, width being second longest
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CMYK – cyan, magenta, yellow, and key (black), four color process
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Custom Packaging — Non-stock packaging designed for specific needs or to feature business branding.
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Die/Cutting Die — A type of tooling that allows for customized branding of packaging products.
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Digital Printer — An industrial scale press with the ability to print in multiple colors simultaneously. Ideal for custom packaging.
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Direct Print — A type of printing that penetrates the surface of packaging, rather than a label or laminate that goes on top of packaging.
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DST - design style tray. Simple Tray used as a Top Cap when shipping pallets
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Four Color Process – print process using CMYK to create an image
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Flute Corrugation — The wave-like shapes that comprise part of corrugated board’s overall construction.
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Fulfillment Center — A facility where products are picked, packed, and shipped after customer purchase.
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Lead Time — The amount of time necessary for certain stages within a supply chain to be fulfilled, such as packaging production or product delivery.
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Master Packs — A type of packaging designed to ship retail products to stores in shelf-ready packaging, typically made of corrugated fiberboard.
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Pantone – also known as PMS. The exact color match of a specific color.
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Paperboard – paper stock for printing
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Paperboard Carton Dimensions - Dimensions refer to the interior of a carton - length x width x height - Length (L) is the longer side of the opening and width (W) is the shorter. Height (H) is the length between the openings on either end.
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PDQ Display — “Pretty Darn Quick” displays designed for store employees to unpack and shelf merchandise quickly and efficiently.
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POP Display — “Point of Purchase” displays designed to promote products with stylish signage near the checkout line.
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Point (pt) - thickness of paperboard; 0.001”=1 point
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Shroud (wrap) - 2-piece “L shaped” sheet of corrugated used to wrap the perimeter of each pallet when shipping
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SKU — “Stock Keeping Unit,” generally refers to different packaging versions of related products.
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Substrate – a type of material
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Small Run — A limited order of packaging, the minimum amount of which varies from manufacturer to manufacturer.
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Tooling — Physical material that helps to make custom packaging, such as a die or mold.
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Thermoformed plastic – formed plastic to a specific shape or size
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Trim - sheet size of litho
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Unit box – a carton to hold a selling unit.
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Virgin Board — Brown board that has not been bleached white or dyed another color.
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Web — An unbroken sheet of paper or paperboard.

OUR TYPICAL PROCESS
This is our high level start to finish process to get an order (PO) and then execute it for our customers!
THE PROCESS
How we make "samples" for customers - structural design and cutting table
ITS ALWAYS BEST TO GET PHYSICAL SAMPLES FROM OUR CUSTOMERS TO DESIGN A BOX OR DISPLAY AROUND. Quite often customers have outdate dimensions or the product doesn't look and feel the same in person as it does on screen. Request samples!
Once our team understands the retails of the project, we typically need to show our customer or prospect a sample of what we are going to sell them.
The packaging industry uses "cutting tables" to create samples and prototypes. First, our team or vendor creates a dieline (the flat version of the box or display) and then uploads it to the cutting table to cut and make the sample. There is no tooling involved and creates for a fast and typically free process for our customers.





