This article is Number 13 of the Packaging Made Simple blog series, inspired by the principles outlined in my Amazon bestselling book Your Amazing Itty Bitty™ Guide to Packaging Made Simple. Each post dives deeper into the topics from the book, offering actionable insights and practical tips to help you create packaging that not only looks great but also works seamlessly for your brand and customers.

Printing is where your packaging vision becomes reality. This is a huge topic, but for this series, I’m keeping it short and sweet. After weeks or months of design and preparation, the print production stage is what transforms your ideas into tangible packaging that customers will see, hold, and interact with. But print production isn’t as simple as hitting “print” on a computer. It’s a detailed process that requires precision, expertise, and collaboration with your supplier.

Understanding the basics of print production can help you navigate this critical step with confidence. By learning how different printing methods work and what factors impact the final result, you can ensure your packaging looks as professional and polished as you imagined.

The Basics of Print Production
At its core, print production involves transferring your packaging design onto the material, or substrate, using ink or toner. The process varies depending on the type of material you’re printing on (such as paper, plastic, or metal) and the printing technique used. Each method has unique advantages and is suited to specific applications, so choosing the right one for your project is key.

The main printing techniques for packaging include offset printing, flexography, screen printing, gravure, and digital printing. While the technical details of each process differ, the goal is the same: to replicate your design accurately and consistently across all pieces of packaging.

Common Printing Methods Explained

Offset Printing: Often used for paperboard packaging, offset printing delivers high-quality, sharp images by transferring ink from metal plates to a rubber roller and then to the material. This method is ideal for large runs where consistency and detail are critical.
Flexography: Flexo printing uses flexible plates to transfer ink directly onto materials like corrugated boxes or plastic films. It’s fast, cost-effective, and works well for both large-scale production and flexible materials.
Screen Printing: Screen printing applies ink through a mesh stencil onto the substrate, making it great for bold, vibrant designs on rigid materials like glass, metal, or thick paper.
Gravure Printing: Known for its precision and detail, gravure printing etches the design onto a cylinder, which then transfers ink to the substrate. This method is often used for high-volume projects with intricate details.
Digital Printing: The most versatile and accessible method, digital printing uses inkjet or toner to print directly onto the substrate without plates. It’s perfect for small runs, prototypes, or projects requiring customization.

How the Production Process Works
Before actual production begins, all of the specs and processes are entered into the production system. This sets up the job ticket and all departments will know what they’re doing. The print production process begins after your production art has been proofed and approved by you. Your supplier will use the approved files to create printing plates or digital files, depending on the chosen print method. Once the equipment is set up and we’re ready to go, test or makeready sheets are run to ensure color accuracy, alignment, and consistency.

After the makeready sheets are good to go, full production begins. For methods like offset or flexography, the paperboard is fed through large, high-speed presses that transfer the design using ink or toner. Depending on the complexity of your project, additional steps like foil stamping and embossing may be performed after printing to complete your decoration part of production. From there, die-cutting, folding, gluing and final packing into master cartons are done

Factors That Impact Print Quality
Several factors influence the quality of your printed packaging, and understanding them can help you achieve the best results.

First, the material you choose plays a significant role. Some substrates absorb ink differently or require special coatings to enhance printability. The type of ink or toner used also affects the final look, with options like water-based, solvent-based, or UV-cured inks offering varying levels of vibrancy and durability.

Color management is another critical factor. To ensure consistent colors across all pieces, suppliers often use color matching systems like Pantone or CMYK as well as the G7 certification. Finally, the scale of your production run and the complexity of your design can impact both costs and timelines, so it’s important to balance your goals with your budget.

Conclusion:
Print production is the step where all your planning, design, and preparation come together to create the physical packaging that represents your brand. By understanding the printing methods and factors that influence the process, you can make informed decisions that ensure your packaging meets the highest standards of quality and professionalism.

Curious about how printing can bring your packaging to life? I’d love to talk to you - please reach out to me via email here.