Structural Design

Graph-ically Speaking

Graphic Design

Our team of graphic designer are not just a bunch of multi-media degree or certificate holders. We tested their creativity first and then their familiarity with the softwares. So be ready to get your visions and designs realised in the best possible manner. Starting from your design concept to the final product, we will not just deliver packaging material but artworks on corrugated canvases.

Measure With Pleasure

Structural Design

Structural design is integral to manufacturing of boxes. While we would attempt to blow you away with our creative calibre, we equally understand the importance of having a technically sound structural design in place. Whenever an order is given to us, our team of adept technical experts measure and understand your box idea and requirements and make them come ‘alive’ basis the right rigidity, weight, load strength and temperature tolerance required.

Inks Involved

Getting into the Nitty-Gritties of Graphics

Zeroing in on a design isn’t enough. It only blows the whistle for the production process to start that actually passes through a number of rounds. The list below will only inform you the level of technical accuracy that we take care.

  • Be assured about the software that we work on. The latest versions of Adobe Illustrator, Acrobat, InDesign, Corel Paintshop Pro and Photoshop to name a few are on auto update mode, and so are we. Therefore, we prefer Vector formats (.ai or .eps) for convivence and impeccable results.
  • If you have images to share with us, we urge you to submit all original source image files from Photoshop or other programs, incorporating the original layered Photoshop files. They come in handy if there are modifications that need to be carried out
  • We take CMYK formats and the files should be saved at 100 per cent size at minimum 150 pixels per inch resolution for reproduction in superior quality. Please check the files before sending. Delete whatever is not required be it unused graphic elements, colours and layers etc. Try and avoid multiple masks.
  • Flexo printing on corrugated materials require custom trapping and file adjustments. Thus, we only seek Illustrator files without any added effects or filters. It is good to identify all colours used in the file and to keep all layers and not flatten them. Here too files sent should be saved at 100% of final size.
  • Fonts often get corrupt and hence fonts should be converted to outlines.
  • Typefaces with fine lines and serifs are not recommended for printing here. These tend to fill in during the printing process leading to blurs and defects. The final decision is taken after evaluating the proofs on the basis on the below mentioned standards:

Minimum type size: 8pt positive, 10pt reverse
Minimum size for ©®™: 3mm positive, 4mm reverse
Line thickness: 1pt positive, 3pt reverse

  • We print line screens from 32LPI – 38LPI. All screen tints, graduated screens and scanned images are subject to dot gain in flexo printing. It is therefore better to create the artwork with the screen values and scans as necessary for the final image. As part of the technical process, it is then adjusted to account for specific press gain. The minimum printable dot is 7 per cent and can go highest to 70 per cent. Screen values over 70 per cent often fill in to solid.
  • In case you wish to give an approved dieline, do make sure that the artwork is created on the Print Side of the dieline. It is often noticed that most dielines are built showing the inside view. Also be cautioned not to apply any trapping to your job, these differ and are sorted according to the press specifications.
  • If you need barcodes on the boxes, then we need absolutely exact specifications. You could put a fake one “for position only” code on the layout according to guidelines that you must follow. Include the number sequence for each code somewhere in the file. The bar code is a must to run with the web. The bars should be pointing in the direction of the lead edge on the dieline. Sometimes resizing is carried out to meet the minimum size needed to print. Our team would generate a digital master code as per the press specifications and place this in the file.
  • Another thing that we always ensure is that the artwork on all regular slotted cartons (RSCs) must be kept 10mm from all scores. Also, additional registration and print production marks may need to be added to the artwork. These are usually hidden on minor flaps as much as possible; basically, we apply these as per specifications.
  • While submitting disk files please note that they must be accompanied by a colour hard copy of the file on the disk. You could give us a reduced proof for seeing the printability. However, all email and internet transfers should be accompanied by PDF proofs. Moreover, if you submit PDF files as artwork, do not use any security. All fonts must be outlined.
  • Be warned, that low resolution jpegs, MS Word, Excel and Powerpoint files are not acceptable file formats.
  • The files can also be sent directly to us through email or wetransfer.

Types of Printing

Printing Method   Description    Benefits  
Flexo Line Entry level printing on corrugated materials. This enables the addition of brand or package content information to the surface of the box. The graphics tend to be basic line art and text, ranging from one-three colours. Cost-wise this is considered easy on the pocket.
Flexo Process This particular process is used for advanced graphics that employs the 4 main process colours. This technique provides a clearer visual outcome and facilitates photo quality images to be used. Since in this method, 4 colour print plates are required, the total print plate costs tend to be higher than the Flexo Line. The minimum run quantities emerge to be much higher in comparison to Flexo line.
Flood Coated Akin to its name, it allows the use of a solid 100% coverage of colour. This is usually used with POP displays and packing for retail purposes. Flood coats can be applied with stock print plates. That saying, die costs get cancelled for the order.
Label Laminate This is made by gluing printed sheets to the outer surface of the corrugated layer. This enables the treatment of a glossy process colour (photo quality) image and is a better option cost wise. This is ideal for lower to medium quantity runs. The label size is limited by the maximum sheet size. The outcome is very convincing. This provides an effective result and is at par with high end packaging. Thea labels can be applied as a 100% coverage, or as a spot label in combination with other Flexo line printing process.
Screen Print For all practical purposes, this is an alternate way of applying graphic intensive images directly to the outer surface of the corrugated package. This process is most commonly used for POP displays and retail packaging applications and can be more cost effective is short run quantities. The size limitations are generally bigger than label laminate. Moreover, colour combinations greater than 4 are possible.
Litho Laminate This generates a finished product quite like label laminate. Yet it requires much higher minimum runs like 10-20K. The printed surface is mainly a part of the packaging material, unlike the label laminate which is put on manually.
Preprint This gives us a similar finished product to Flexo process. In this method the client is required to get pre-printed rolls of paper that are used in building linerboard. Engaging this method requires high volume runs and a large investment by the client. Yet it can be a cost-effective way to create amazing graphics at those quantities. This technique is most commonly used in the food and beverage industry.

Corrugated Board Strength

This is the most crucial factor that determines how strong the box should be. And you should be aware of these vital pointers before you go ahead to place your order. One, the nature of the products being packed, two, how much the box is going to weigh? Three, the actual size of the box and four; how the cardboard box will be stored with the goods and be transferred.

Hence, to make things simple for you, we provide customization options when selecting box strength. The first is the flute type and the second is using the edge crush test.

Corrugated Box Flute Types

Corrugated flutes are the S shaped waves or arches of a corrugated box that builds the overall board box. This is aptly called the system of the boards corrugation. Flutes are broadly the reinforcement that make up the board. They run parallel to the depth of the container and give it its rigidity and crushing or stacking power. Apart from providing stacking strength, flutes also provide insulation that protects products from sudden temperature changes. To make you aware, actually larger flutes like A & B profile provide greater strength and cushioning, while smaller flute profiles like D & E provide better printability and foldability.
B flutes have 42-50 flutes per foot and are 1/8″ thick. They provide the second highest arch size.

B flutes provide suitable loading strength and crushing endurance. There are meant for for canned goods and various displays.
C flutes have 39-43 flutes per foot and are 11/64″ thick in strength. They are the medium between A flute and B flute and are very common.
C flutes proffer fitting cushioning, stacking and printing properties. If you were to pack glass, furniture and food items, then these are the ones.
E flutes have 94 flutes per foot and are 1/16″ thick. The board profile is very thin that results in reduction of the box size invariably saving store space.
E flutes bestow the highest crush resistance. Plus they are ideal as a printing surface making them the most preferred option for die-cut custom boxes.

Corrugated Box Construction

We have two solutions for these. You could choose between single and double-wall cardboard construction.

Single Wall is the most common corrugation material – it includes 1 layer of whatever flute type you choose. For regular conditions, single wall construction are appropriate as they are offered from 23ECT to 44ECT.

Double Wall construction, also known as ‘heavy duty’ corrugation material is used for heavy or large objects. A Double wall consists of 2 layers of flutes, usually 1 layer of B and 1 layer of C. They are around 35 per cent sturdier than the routine single wall corrugation type. We also house double wall cardboard boxes from 44ECT to 61 ECT.

Flute Types Flutes/Foot Thickness Advantages
B Flute 42 -50 1/8″ Good cushioning, stacking & printing
C Flute 39-43 11/64″ Good stacking, strength & crushing resistance
E Flute 94 1/16″ Greatest crush resistance & printing surface
E Flute Double Wall Very Thick Can hold very large & heavy items

Edge Crush Test

This is benchmark in testing. The Edge Crush Test is viable technique used to define the “stacking” or “crushing” of a piece of corrugated board. The test is conducted to gage the force that will crush a containerboard standing on an edge. The ECT also calculates the probable compression strength of the container made from the board.

Types of Construction Edge Crush Test Maximum Suggested Load Limit (lbs)
Single 23 20
Single 26 35
Single 29 50
Single 32 65
Single 36 75
Single 42 80
Single 44 95
Double-Wall 48 100
Double-Wall 51 120
Double-Wall 61 140