FOLDING CARTON PRODUCTION PROCESS

Die-Lines and Sheet Layout: Die-lines are flat versions of the box showing what the final 3D box will look like.                                                                                      It shows the locations for die-cutting, folding and gluing while also showing the position of the artwork on the final package.

Sheeting and Printing: Large rolls of paperboard must first be cut into sheets before running through the printing press. Manufacturers will ensure that the grain is running in the direction that will be most efficient and effective for this step. When the sheet enters the press, any imagery and artwork you designed will be inked and coated onto the sheet via offset, digital or flexographic printing.

Post-Press Finishes: Further optional customizations like hot-foil stamping or embossing and debossing are done via specialized machines during this stage to enhance the look of your box.

Die-Cutting: This stage is where many duplicates of your carton are cut from the paperboard sheet. The die is a specialized, elaborate cutter akin to a cookie cutter that will cut the paperboard while minimizing waste and allowing for easy folding where necessary. The manufacturer recycles excess scraps of paper made from this stage to form new paperboards.

Folding and Gluing: The final stage of the converting process is where your box’s flat, die-cut pieces are fed through the machine for folding, pre-breaking and gluing. Some cartons that include transparent windows in the design are applied in-line during this stage. The manufacturer will aim to complete these processes in the fewest passes possible.