The top 10 items US consumers are embarrassed to buy at physical shops include condoms (29%), emergency contraceptives (26%), bed bug spray (26%), head lice treatment (25%), hemorrhoid cream (24%), diarrhea medication (24%), pregnancy kit (23%), bladder leak or incontinence products (23%), menstrual products (23%), and cold sore medicine (23%).

More good news: brands can ship your order without any product identification or company name to prevent couriers or nosy neighbors from discovering what you bought from their store.

And that’s what discreet packaging is all about. 

Discreet packaging uses plain—no conspicuous design or imagery—shipment boxes or mailers with minimal labeling to avoid drawing attention and ensure its contents remain confidential.

Ambiguous Exterior: “Masking” What’s Inside

Discreet packaging uses the following to keep its contents a secret:

1. Plain boxes or bags

You can use plain white, Kraft, or neutral-colored carton mailers, shipping boxes (full overlap or slotted), or bags with little to no branding.

2. Generic/White labels

Discreet shipping labels can feature only a tracking number, recipient’s address, and any legally required descriptions, depending on your product. You don’t have to include your company name or business logo.

3. Stealth packaging

Packaging materials with tamper-proof features aren’t easy to rip open, securing the quality—and quantity—of its contents. They may use special seals and tapes that need scissors or blades to open. This makes it obvious if others besides the recipient attempted to look inside.

Product Categories Requiring Discreet Packaging

Customers are most likely to request or expect discreet shipping for the following categories:

1. Medication and healthcare products

Some health conditions are considered too embarrassing or sensitive that your customers are secretive about them and may prefer discreet packaging for their medicine. Examples include:

• Digestive and urinary problems (diarrhea, constipation, hemorrhoids, incontinence)
• Personal hygiene troubles (body odor, foul breath, excessive sweating)
• Hair and skin trouble (balding and acne)
• Snoring or sleep apnea
• Fungal or viral infection (toes, nails, reproductive organs)
• Pregnancy

Take InControl Diapers, for example. A YouTube video from InControl shows that the adult urine and bowel incontinence diaper brand delivers orders in plain packaging. The box only has a label with your shipment number, name, and address.

2. Vapes

The amended Prevent All Cigarette Trafficking Act (PACT Act) prohibits the shipment of vaping products, e-cigarettes, and similar devices with or without “aerosolized solutions” via the US Postal Service (USPS). 

It also specifies the wording for packaging labels. “Permitted [cigarette/smokeless tobacco/ENDS] mailing—delivery only upon age verification” must appear in all caps on the mailpiece’s address side, based on its mailing guidelines. 

VapeA1 boasts “extra discreet plain box shipping.” The company ships customers’ packages from any of its four warehouses with available supplies that are closest to them.

3. Cannabidiol (CBD)

CBD regulations vary by state but have common features. For instance, New York State’s Office of Cannabis Management and California’s Department of Cannabis Control require CBD retailers to use child-resistant and tamper-evident packaging that encloses the entire product.

CBD packaging shouldn’t contain elements—such as cartoonish or bubble-like fonts and bright colors—that can be confused with candies or snacks and may attract people aged 20 and below. 

Also, the state expects CBD retailers to use packaging material that will protect the content from light and other contaminants that can lead to product deterioration during storage. Both states require graphic markers on the CBD boxes and packaging.

Overall, vendors should accurately indicate CBD levels on product labels to avoid getting warning letters from the Food and Drug Administration (FDA). 

One recent agency study showed that only 31% of 84 CBD extracts sold online bore labels accurately listing the CBD content of their goods. The FDA has issued warnings to 12 firms marketing CBD-related products as of July 26, 2023.

Meanwhile, six companies received cease and desist letters from the Federal Trade Commission for using deceptive marketing for their edible goods containing Delta-8 tetrahydrocannabinol, another compound from cannabis sativa. The packaging resembled the designs of popular snacks, such as Doritos, Cheetos, and Nerds Rope Candy.

Utah-based WholesomeCo shows a discreet but not plain-looking packaging for its medical cannabis.

4. Adult products

Adult products include alcoholic drinks, lingerie, and sexual wellness products or sex toys.

New Zealand-based company Elusive Lingerie tells its customers to specify in the shipping “Notes” section that they want discreet shipping. Otherwise, they’ll get their order in a plain white but branded box.

Standard shipping procedures apply for sexy sleepwear, but for liquor and pleasure toys, consider the following:

Liquor

Like in CBD, state governments set rules for shipping liquor directly to consumers, including the allowable types, maximum amount, and required permit or license. In general, brands can’t send them through the USPS.

Eight states and territories accept D2C shipments of all spirits, according to the National Conference of State Legislatures website, which lists the details of each state’s requirements:

• Hawaii
• Nebraska
• Kentucky
• West Virginia
• New Hampshire
• Rhode Island
• Florida
• District of Columbia

In most states, shipments must be conspicuously labeled with these wordings: “Contains alcohol: Signature of person age 21 or older required for delivery.” 

Labels on alcohol shipments for New York residents must also have the same words but must end with “Not for Resale.” Meanwhile, the labels on North Dakota-bound shipments don’t require the phrase “Contains alcohol.”

Pleasure toys

Brands should check state laws on shipping sex toys, the sale of which is banned in Alabama (due to its Anti-Obscenity Enforcement Act of 1998), Texas, and Georgia. In Texas, these adult products should be identified as “novelties.” You’ll find them sold at local novelty stores.

Bonjibon uploaded a video on TikTok showing its “super boring” white label-plain packaging for its sexual wellness products.

Expensive or luxury goods

Luxury or high-end products include:

• Fashion items: watches, jewelry, precious stones, expensive perfume, designer clothing, bags, and shoes
• High-tech gadgets: headphones, tablets, laptops, electronics, drones, video or film production devices, medical equipment
• Artwork: prints, paintings, sculptures, collectibles

6. Political items

You can ship individual candidate campaign products to thank donors and supporters or send them in bulk ahead of mass rallies and sorties. These items can include:

• Pins
• Magnets
• Bumper stickers
• Doorknob hanger tags
• Pens
• Notepads
• Stress balls
• Hand fans
• Sunglasses
• Wristbands
• Lanyards
• Keychains
• Umbrellas
• Caps and hats
• Banners
• Balloons
• Table throws
• Mugs
• Tote bags
• Shirts
• Yard signs
  

3 Steps for Memorable Unboxing with Discreet Packaging

In customizing your discreet packaging’s interior, you can go all-out on box design, colors, and messaging. Get as creative as you want to provide a unique unboxing experience by trying these steps:

1. Greet your customer

Print “Thank you,” “Hello,” or any other catchy and personalized message at the back of your box’s cover or lid to acknowledge your client’s purchase and to introduce your brand further.

Your business name, logo, and other particulars can also fill this spot.

2. Wrap their order in custom tissue paper and a brand sticker

Use tissue paper and stickers bearing your logo, brand name, colors, and patterns to make your customers remember your business even after they’ve used up your product.

3. Include promotional inserts

Add custom promotional inserts based on your engagement and customer acquisition goals:

• Thank buyers with a customized insert instead of printing a message on the back of your box’s lid.
• Get client feedback on their purchase and connect with them online through social share inserts.
• Include a referral card to the package encouraging current customers to refer their friends to your company with a purchase discount.

You can also use these inserts for instructions on using the product or to share your company history, online or offline events, and upsell opportunities. 

How Discreet Packaging Boosts Your Business

You can reap the following benefits when you offer discreet packaging:

Privacy

Confidentiality works two ways—by concealing your business name and the specifics of your customer’s order, you guard your reputation and your buyer’s privacy.

Some frustrated clients take videos of discreet shipping failures. Prospects who come across such videos are likely to get turned off when they discover your brand doesn’t ship as discreetly as you claim.

Meanwhile, contented customers can polish your image when they leave positive feedback on your review forms and social channels for your expert handling of their sensitive orders.

Security

Discreet packaging isn’t just for embarrassing body-related products but also for high-end items. Generic-looking packaging can prevent theft, damage, or destruction.

Box interior optimization

Although you must be unobtrusive on the outside, your box can bear all your branding elements on the inside. 

Optimize your packaging box’s interior by printing your brand colors, logo, slogan, or personalized message on it. You can also wrap your product with custom tissue and seal it with a custom label or sticker. 

Be intentional with your packaging inserts—use eco-friendly materials for dividers or holders, and include thank you and social share request cards to promote extended engagement with your shoppers.

Available Courier Services for Your Discreet Packages

The country’s top couriers treat various product categories differently. Below is a summary of their services:

You can also opt to work with a fulfillment center, which offers discreet labeling along with shipping services.

Future-Proof Your Business with Discreet Packaging

With 24% of retail purchases expected to happen online by 2026, offering delivery options to your customers—including discreet shipping—can prevent you from being pushed aside by fierce competitors. Over two million retailers operate in the country according to the Census Bureau.

Surprise your customers—or at least don’t make them regret shopping with you—by working with seasoned packaging suppliers that provide white-glove treatment from box type selection to prototyping.

Refine Packaging specializes in customized mailers and shipping boxes, including packaging for brands that seek a balance between a discreet exterior and an impressive interior box design.

We can work with a print-ready design that aligns with our artwork guidelines to ensure a smooth and speedy production process. At the same time, our packaging design specialists can provide expert advice, from box structure to packaging inserts and inside printing. These accomplished graphic artists and engineers can apply their expertise and skills to make your packaging a trust-building vehicle for your brand.

Your journey with us includes 2D and 3D mockup development, which allows you to examine and test your box in its folded-up form before production. Contact us today to discuss your discreet packaging needs.

The post Discreet Packaging: The Ultimate Retail Embarrassment Cure appeared first on Refine Packaging.

Although you can give this task to your graphic designer and print manufacturer, knowing the industry’s standards for color can aid your selection process and level expectations about the printing outcome.

This article is primarily about CMYK, but we’ll also touch on the other two most prominently used color modes in the design world—RGB and Pantone. Color models are the building blocks that represent an image and have their own gamut or color ranges. They achieve unique levels of color detail according to their number of channels or colors. Their comparison can deepen your appreciation of CMYK as the most effective color model for printing.

Defining CMYK

CMYK stands for the four ink colors used in printing—cyan, magenta, yellow, and black. The CMYK system blends these colors to create about 16,000 variations. In the color wheel:

• Cyan falls between blue and green, but most people see it more as the former color. It’s similar to sky blue or the aqua blue color seen in tropical ocean waters.
• Magenta falls between red and blue, but most consider the color closer to red instead of blue. It’s comparable to fuchsia and hot or deep pink. People associate this color with bougainvillea flowers and orchids.
• Yellow is the lemon yellow, canary yellow, and gold hues we see in nature, such as sunflowers, daffodils, and sunshine.
• Black is the color of coal, volcanic rock, and some gemstones like obsidian and onyx. The other meaning of “K” is “key” because the black ink plate provides fine details, depth, and contrast in the resulting image. Thus, “key plate” is the other term referring to the black plate.

In theory, mixing cyan, magenta, and yellow results in black. In reality, however, their combination results in a muddy dark gray. Moreover, a 100% three-color blend soaks the paper in ink, slowing down the drying process.

How Does CMYK Work?

When you bring your packaging design to a commercial offset printer such as Refine Packaging, the company separates your file into component colors using what’s known as the color separation process. 

Each CMYK ink color has a separate printing plate, and the ink transfers or offsets from this plate onto a rubber blanket and then on paper as tiny dots. The colors become solid and continuous as the dots overlap until the four-color process or process printing is complete.

Meanwhile, digital printing doesn’t require color separation. The ink goes directly onto paper instead of plates, making them a cost-effective option if you have a lower quantity printing order.

The printer copies the image from your file. From there, individual CMYK color droplets produce the illusion of a colored image. Inkjet printers use ink while laser printers—used in commercial applications—use toner.

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RGB and Pantone Systems

To improve our understanding of CMYK, we must compare it with the RGB and Pantone color models.

RGB

Graphic and packaging designers refer to RGB—red, green, blue—as desktop colors because they represent the colored lights used on electronic displays (computer monitors, mobile devices, TV sets, and digital cameras), whether it’s for videos, websites, and apps.

Moreover, this color model offers the most expansive range of colors—16.7 million in all. As a result, discrepancies occur between colors on screen and print, as CMYK has a narrower color gamut.

RGB vs. CMYK: Additive vs. subtractive color models

When comparing RGB and CMYK, it’s important to know that RGB is an additive color model, while CMYK is a subtractive color model.

RGB is an additive color model that combines various intensities of red, green, and blue light to produce other colors. You get pure white when you mix RGB colors at their maximum brilliance. Meanwhile, you must combine the three colors at their lowest intensity (minimal light) to produce black.

The opposite happens with CMYK, a subtractive color model. Unlike electronic screens, paper isn’t transparent and doesn’t allow light to pass through. One must apply less color to see white. Images appear with a lighter tone when paper receives fewer ink dots.

Because CMYK inks only reflect light—unlike RGB colors that emit them—it’s best to convert RGB images to CMYK for accurate printing.

Pantone

The Pantone Matching System (PMS) follows a numbering system for accurately and quickly identifying colors for printed materials, fabrics, and paints. Every Pantone color—2,161 of them—has a unique code corresponding to a pre-mixed ink formula, aiming to produce the colors consistently across different projects. These colors include fluorescent and metallic colors, which aren’t available in the CMYK and RGB models.

When you ask a professional printer to match your specific PMS colors, its staff adjusts the digital printer’s colors until the result matches your PMS swatch.

Spot Color

Spot or solid color is another name for the color printed on paper using premixed ink to match a PMS, unlike the CMYK process, which involves four layers (one for each color). In effect, the blending of colors happens before and not during printing for spot colors.

Spot colors consist of a name or number and end with either a C (coated) or U (uncoated), referring to the paper stock type on which to print it.

When to Use CMYK and Spot Color Printing

Here are some tips to help you determine when to use the four-color or spot-color printing technique:

CMYK

CMYK or process printing is ideal for projects involving so many colors that using several spot inks would be impractical and expensive. Examples include full-color photographs, paintings, and very complex colored images.

CMYK—the most widely used standard digital and offset printing system—is also cost-effective for low-quantity orders with multiple hues and gradients. However, color-matching won’t be as precise as spot colors. Some printers offer a broader range—also referred to as extended or expanded color gamut—that includes orange, green, and violet to improve brightness and realism.

Spot Color

You can use spot color printing for jobs requiring a few (one or two) exact colors, such as your brand colors and business logo, and colors outside CMYK’s color range—pastels, metallics, and fluorescents. Spot colors would cost you more per order because they require ink colors with specific formulations and a separate plate.

CMYK and Spot Printing

You can use both techniques simultaneously when, for instance, you must print an image (CMYK printing) and your company logo or product name (spot color) close to each other. Another example is when you want to increase the intensity of a specific process color or coat portions of a full-color image with a clear varnish, which is a spot color.

Below is a quick reference of the three color models—their characteristics and uses:

Tips for Improving Color Accuracy When Previewing CMYK Colors on Your Screen

Because RGB can display more colors than CMYK, the way you see a design or image on the screen may not be accurately reproduced through the CMYK print process. But you can reduce the discrepancy between the two by following these tips:

1. Calibrate your monitor and perform soft proofing

PC and laptop manufacturers gear factory settings toward film viewers and gaming fans, resulting in high brightness, high contrast, and saturated colors.

Thus, recalibration is necessary when working on packaging designs. Adjust your device’s color settings (“color profiles” on Mac) to match your color standard, particularly the brightness or luminance of your display. Your printouts may appear dark if you’ve been designing and editing on a very bright monitor. Most monitors have built-in calibration tools

D50 is the recommended white point or white balance for LCD monitors when working with still images. White point is the temperature setting that determines the coolness or warmth of your whites.

2. Perform soft proofing

Check your software’s color management system. Adobe Photoshop and Illustrator’s soft proofing feature lets you view your artwork the way it will appear on a surface when printed by the CMYK method.

3. Refer to color swatches and guides

Printed samples of colors are a handy reference when checking designs and images on screen and paper.

4. Print a test copy

Make a printed proof to discover color problems early and avoid surprises from your printer. You can then include the printout closest to your envisioned colors when you submit your digital file to your printing partner.

Use high-quality ink and paper to avoid getting faded results. You should also check your printer nozzle and cartridge in case of banding. Otherwise, you can go to a print shop to produce a test copy for you. 

Preparing Your File for Printing

After learning how to make your screen display your packaging design the way it would appear on your chosen material, you must now prepare your file for the printers.

Converting Files to CMYK

Industrial printers typically ask for files in CMYK mode so you must check your packaging design and convert it to CMYK if it’s in the RGB mode. The conversion method will depend on your software. Below, we list the steps required for CMYK conversion for the most widely used platforms.

Adobe Photoshop

1. Open your image file.
2. Click on “Image” on the menu at the top of your screen.
3. Hover over “Mode” to display the options and click CMYK.

Adobe Illustrator

1. Open your image file.
2. Click on “File” on the menu at the top of your screen.
3. Mouse over “Document Color Mode” and select CMYK.

Adobe InDesign

1. Open your image file.
2. Click on “File” and choose “Export.”
3. From the options, select PDF/X-1a:2001. This automatically converts colors to CMYK.

Note that converting from RGB to CMYK may result in some color data loss and shifts because the CMYK system can’t accurately represent all RGB colors.

Communicating With Your Printer

Printing companies use different machines, so get to know their requirements, limitations, and preferences before sending your design. Ask your printer about their artwork guidelines, which typically includes the correct file format, size, resolution, color system (some have a unique PDF Preset), printing method and technology, as well as their expectations and deadlines.

Due to technological advancements, some printers can work with files in a specific RGB profile, such as sRGB IEC61966-2.1, which is compatible with most software and devices. When they receive your file, they convert it to CMYK.

Best File Formats for CMYK

We can’t emphasize enough that you’ll need to ask your printer for the file format required for your print project. Nevertheless, we list some of the best file formats below:

.ai (Adobe Illustrator)

Illustrator is the industry standard for vector-based, scalable designs, making it a standard source file for CMYK.

.pdf (Portable Document Format)

PDF preserves all the color and formatting information in a document and can handle raster and vector images. The file format is also compatible with most programs, making it ideal for CMYK printing.

.eps (Encapsulated PostScript)

EPS is a vector file format and a great alternative to .ai because it opens in non-Adobe software.

.cdr (CorelDraw)

CorelDraw files contain images created using this software, which can also generate text, shapes, and effects. You can convert CDR format to .ai., .pdf, .eps, and .tiff.

.tiff (Tag Image File Format)

Virtually all image-editing and page-layout applications support this flexible raster image file. The format allows you to choose between CMYK and spot colors. 

The Reliability of Your Custom Packaging Manufacturer Is Key to Consistent CMYK Printing

Read our ultimate guide to packaging terms and definitions to help you get up to speed with industry terminology as you create your own custom boxes.

Industry insiders predict that the U.S. packaging market will rise by 2.88% to $222.59 billion by 2028 and keep its status as a leading growth driver in the offset printing press market. Digitization has penetrated this printing method, putting it head-on-head with digital printing. Computers now create printing plates, which undergo laser exposure resulting in improved image quality.

Moreover, analysts project a 5.19% growth in the North American cardboard market until 2027.

Because color is the top influencer in buying decisions—at least 85% of consumers say so—your printer must have a proven record for consistent quality output.

Refine Packaging’s customers and brands have relied on our high-spec manufacturing process for their marketing needs, from display and showcase exhibit packaging to shipping and mailer boxes, corrugated packaging, and custom labels and stickers.

Our offset printers work with CMYK and PMS spot colors. If your design is in RGB mode, we’ll convert it to CMYK. We have artwork guidelines to make it easier for you to prepare your file. Also, we’ll show you a digital proof before printing, so you can check whether the colors replicate or are close enough to your initial choices. Besides offset printing, we offer UV coating, foiling, and embossing/debossing.

Refine Packaging is the top choice for the world’s Inc 5000 and Fortune 500 companies. With super fast production times, affordable pricing, and a sky’s the limit attitude, we’ll help you turn your custom packaging into a competitive differentiator. Contact us today and a dedicated packaging specialist will guide you through every step of the custom packaging process without breaking a sweat.

The post What is CMYK? How to Use the CMYK Color Model for Printing appeared first on Refine Packaging.

If you ship out a high volume of orders weekly or daily, you must choose your paper packaging wisely. Safe shipping leads to memorable unboxing and lower product returns, resulting in customer loyalty and profitability. 

This guide on cardboard and corrugated carton boxes aims to compare these two packaging types so you can select the most effective way to package your product or kits.

Distinguishing Cardboard Boxes from Corrugated Carton Boxes

It’s important to know what packaging box suppliers and printers refer to when they discuss cardboard and corrugated carton boxes. They’re folding box types that require assembly, unlike rigid or set-up boxes. Learning more about their individual qualities will help you decide which paper packaging suits your product.

Cardboard packaging (folding carton boxes)

Cardboard or folded carton boxes use heavy paper pulp or thick paper stock. Shoe boxes, cereal boxes, milk cartons, toilet paper rolls, and facial tissue boxes use this material.

Best uses: Cardboard boxes make great secondary packaging or the material surrounding your primary packaging, such as a glass bottle or plastic tub. Moreover, printers find it easier to print intricate designs on cardboard boxes than on corrugated ones due to the flat surface of the former.

You’ll also spend less on cardboard packaging. However, this material is more advisable for lightweight products.

Corrugated carton packaging

Corrugated carton boxes consist of three-layered sheets: a corrugated (rippled or wavy) medium—or flute—sandwiched by two flat boards or “liners.” Pizza and home appliance brands and their distributors deliver or ship products using this packaging type.

Best uses: Due to their structure, corrugated packaging is ideal for stacking, storage, and shipping. You can also reuse and recycle them more times than cardboard carton boxes.

Both packaging types are sensitive to moisture. Although corrugated boxes have more layers, you must consider this factor’s possible impact on your products should warehouse or shipping staff leave your box—whether cardboard or corrugated—in an exposed or open area.

Thickness Ranges

Cardboard and corrugated carton packaging differ in density. Suppliers typically use paper stock with a thickness of around 0.5 millimeters to three millimeters for cardboard carton boxes. Meanwhile, corrugated boxes can reach up to around seven millimeters thick.

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Here are the most common flute sizes (in increasing levels of thickness) and their measurements:

• F flute: 0.6 to 1 millimeter or 1/32″ with 125 to 128 flutes per linear foot
• E flute: 1.5mm or 1/16″ (.0625″) with 90 flutes per linear foot
• C flute: 4mm or 11/64″ with 41 flutes per linear foot
• B flute: 3mm or 1/8″ (0.125″) with 49 flutes per linear foot
• A flute: 5mm or 1/4″ with 36 flutes per linear foot

Most corrugated shipping boxes use the C flute (80%). Meanwhile, E and F flutes are most suitable for high-quality printing applications due to their lower density.

Other flute sizes include:

• D flute: 2mm (.085″)
• S flute: 1.9 to 2.2mm
• EB flute (combines E and B flutes): 3.8mm to 4.3mm or 4.5mm
• BC flute (combines B and C flutes): 6mm to 6.7mm

Furthermore, corrugated carton packaging comes in four board options:

1. Single face boards consist of two layers—a liner and a corrugated layer. Their most common use is interior packaging.
2. Single wall boards are the most common corrugated box style, featuring two outer liners and a fluted or corrugated layer.
3. Double wall boards contain three liners with two corrugated flutes in between them. This extra sturdy construction makes them ideal for industrial use.
4. Triple wall boards consist of four liners and three corrugated layers. They can serve as alternatives to wooden crates. This board type is advisable for chemicals and products requiring special handling.

Materials

You can choose from an array of materials for your cardboard and corrugated carton boxes. Let’s look at the available choices for each box type.

Cardboard (Folded Carton) Box

Here are the most common paperboard grades for cardboard packaging:

Solid bleached sulfate (SBS)

SBS is a tear-resistant, white premium-grade paperboard with a naturally occurring clay surface. This paper grade consists of 80% freshly harvested wood chips and 20% recycled materials that underwent chemical processing and bleaching. Available in one (C1S) or two coated (C2S) sides. You’ll find this packaging used for cosmetics, medical products, perishable bakery products, and milk and other dairy products.

Solid unbleached sulfate (SUS) or coated natural Kraft (CNK)

SUS undergoes the same chemical processing as SBS, except that there’s no bleaching, leaving the paperboard’s backside brown. In front, you can use lithography or gravure printing on its smooth, white surface.

Coated recycled board (CRB)

CRBs use 100% recycled paper made from recycled fibers. Its top ply generally contains white fibers with a clay-coated finish, while its backside is gray. This paperboard is a favorite choice for cereal, dry bakery goods like cookies and crackers, laundry detergents, dry food such as pasta, and hardware supplies.

Other paperboard options include:

• Uncoated recycled board (URB) has no coating in the front or on its backside.
• Coated unbleached Kraft (CUK) contains at least 80% virgin fiber.
• Clay-coated news back (CCNB) has a clay-coated front and gray or tan back, depending on the fiber used.
• Thermal mechanical pulp (TMP) features a middle layer of mechanical pulp between two chemical pulp layers. The bleached top layer is coated with pigment, while the translucent back is cream, taking on the color of the middle layer.

Corrugated Box

The most common materials used for the outer and liners (or walls or boards) of a corrugated box are:

Kraft liners

Kraft liners are stiff and strong materials made from 70% to 80% chemical pulp fiber from softwood trees (pine, fir, and spruce). Most outer liners use Kraft paper because of their smooth, finished surface, which allows for easy printing. They’re available in brown, white, bleached, mottled or speckled, and birch-faced.

Test liners

Because test liners use partly or 100% recycled instead of virgin (direct from the source) fibers, they’re not as strong as Kraft liners. Suppliers typically use these as inner liners. Test liners also cost lower than Kraft paper.

Semi-chem (pulp and sulfur) and waste-based (recycled) paper grades

These paper types are the most widely used fluting materials due to their high strength.

Box Styles

Here are some of the most widely used styles for cardboard (folded carton) and corrugated carton boxes.

Cardboard (Folded Carton) Packaging

Straight tuck

Straight tuck boxes have top and bottom closures attached to the same side of the box. The closures—which typically feature slit locks near their end flaps—fold from front to back in the same direction.

Lock bottom

Lock bottom or 1-2-3 bottom boxes have a tuck top panel and bottom flaps that push into each other to lock. Its more secure bottom makes the packaging ideal for heavier items (wine, large candles, or electronics). The numeric name of the box refers to the three steps needed to assemble it.

Crash bottom

Crash bottom boxes, also known as auto-lock or auto-bottom boxes, have tuck-top closures and pre-glued bottoms, making them the most secure box type for heavy objects. Its base automatically folds and closes, unlike the lock bottom box, which needs manual assembly.

Reverse tuck

A reverse tuck box’s top and bottom closures are on opposing sides of a box so that they fold in opposite directions.

One-piece tuck top

One-piece tuck-top boxes are similar to mailer boxes, only they’re made of paperboard. They have a top opening with tucking tabs that fold into the bottom of the box. You’ll find many baked goods like donuts sold in this box style.

Two-piece (Simplex or Kwikset tray)

A two-piece box consists of a tray and a lid with double-wall structures. They can come with inserts, making them a highly recommended solution for sweets, luxury products, or kits.

Hanger (hang tab) style

A hanger box is a reverse tuck box with a hanger panel extending from the back, allowing you to hang it on a hook or stand for retail display.

Gable top (handle or carrier box)

Gable top boxes have a crash bottom and a top handle. It’s a popular style for packaging gifts and food.

Pillow style

A pillow box has a curved shape with flap closures on the sides that bend in. They can contain lightweight and small products, such as jewelry, hair accessories, soaps, party favors, or event giveaways. 

Corrugated Packaging

Regular slotted container

A regular slotted container box’s top flaps or closures have equal lengths. A gap exists between the inner flaps. However, the outer or lengthwise flaps meet the middle of the box when you fold them in to close.

Center special slotted container

Unlike the regular slotted container, the outer flaps don’t share the same length as the inner flaps, which meet at the center of the box (hence, the name). The “gap-less” closures provide a more level and stable base and top.

Half-slotted container

People often use the half-slotted container for open storage, as it follows the same structure as a regular slotted container except for its top, which has no flaps.

Overlapping slotted container

This box type is like the regular slotted container, but its outer flaps overlap by at least an inch. You can use staples or adhesives for closing securely. This overlap becomes an indispensable feature for boxes with a greater length than width, which creates a wider gap between the inner flaps.

Fully overlapping slotted container

This style is like the regular slotted container, except that the outer flaps’ length is equal to the box’s width and fully overlaps when bent inward to close. The overlapping flaps act as cushioning in case of stacking.

Center special fully overlapping slotted container

This box type combines the features of the center special slotted and the fully overlapping slotted boxes. Its inner flaps meet in the middle—offering a level, “gap-less” base—while the outer flaps overlap.

Telescope box

Telescope boxes have lids that fit snugly by at least two-thirds the depth of their bottom pieces.

Design style container with a cover

This style is like a telescope box, but the lid extends less than two-thirds the depth of the body.

One-piece folder

A one-piece folder is typically one large corrugated sheet that you crease and fold until you get a flat and unbroken base. You can use this packaging for shipping books and printed products.

Auto-lock or 1-2-3 bottom container

Auto-lock boxes in corrugated packaging share the same pattern as cardboard or folded carton boxes. Its four die-cut bottom flaps snap into place, folding inwards over one another and then “lock.”

This table shows you the most popular box styles discussed above at a glance:

Eco-Conscious Preferences Rising

Paper packaging scored the highest in the “Trend Tracker Survey 2023,” whose respondents reached over 10,000 people from 16 nations worldwide—including the US, Europe, South Africa, and South America. Participants rated packaging materials (paper/cardboard, metal, plastic, and glass) according to 15 attributes (physical, visual, and environmental features). 

Paper and cardboard received 10 for their compostability (76%), eco-friendliness (55%), and recycling ease (49%). 55% of US-based respondents plan to buy more from companies that stop using plastic for their packaging. Moreover, 47% are considering avoiding stores that don’t actively reduce non-recyclable packaging.

As a result, 75% of the world’s organizations have made “sustainable packaging commitments.” The percentage is higher among consumer goods firms (80%) compared to B2B and industrial companies (66%).

Amid consumer consciousness and robust online sales, industry insiders predict the paper packaging market’s value will hit $3.8 billion by the end of 2023.

Some food for thought: recycled paper makes up over two-thirds of the paper—over 50 million tons—that America uses. Some sources say the amount of paper the US recycles daily can fill boxcars lined up for 15 miles.

Trends in Paper Packaging

Various companies have revised their original box designs to lower their carbon footprint. Discover how businesses are customizing their packaging:

Smaller, lighter box designs

Continental AG, a world leader in automotive parts and tires, has redesigned its timing belt (for vehicle engines) with water pump kits to a smaller size, allowing shippers to transport nearly 70% more boxed kits per pallet.

Meanwhile, German firm Jägermeister has begun using corrugated boxes—replacing its solid board packaging—for shipping its herbal liquor product. 

Grass cardboard

Paper and cardboard factories are turning to grass cardboard fibers from nature reserves to make carton packaging materials. Dried grass pellets compose up to 50% of their mixture that also contains recycled or virgin fibers. Factories using grass can save up to three cubic meters of water per ton of cardboard.

Seed or plantable packaging

Plantable packaging does what its name claims it to be. Users can grow the seeds (such as herbs, lettuce, carrot, chamomile, or wildflowers) embedded in the box—typically made of recycled paper. Pangea Organics, a skin and body product line, and Bloom Everlasting Chocolate are two businesses that have adopted plantable packaging. 

Compostable film for window boxes

Fresh produce brands, such as SoFruPak, have introduced cardboard trays with lids that have compostable cellulose film coating inside. The plastic substitute works well with cutout windows.

“Self-healing” boxes

Packaging providers have begun working on smart packaging concepts featuring a web of sensors that can alert delivery firms about sustained damage, based on how leaves react to external stimuli. The futuristic material can stretch and thicken itself to repair the damaged spot or any tear after unboxing to ensure their reuse.

Current Challenges Faced by Cardboard and Corrugated Box-Making Firms

Despite dynamic strides in paper and carton recycling, packaging companies face the following challenges:

1. Fluctuating raw material prices

The price of raw materials—paperboard types and adhesives— dictate the rate of production cost.

2. Last-minute orders

Suppliers need high-speed machines to fulfill orders for an additional x number of boxes that clients inform them about at the end of the day.

3. Demand for “no-minimum quantity” projects

Some packaging firms allow customers to determine order volumes to sustain their business.

4. Compatibility between older equipment and new materials

Factories must test new materials on their existing machines to ensure they won’t negatively affect performance.

5. Alternative packaging materials

Carton boxes compete with flexible packaging and molded pulp, which can be more lightweight and versatile in size and shape options.

6. Environmental concerns

The majority of the public considers paper-based packaging as more eco-friendly than plastic. However, producing cardboard requires more water than making plastic. Some sectors have also raised the alarm about food getting contaminated by printing inks, coatings, and paper-bleaching chemicals.

Choose a Packaging Manufacturer with Dual Expertise and Capabilities

When searching for a shipping solution for your product, box printing companies like Refine Packaging can provide support when you’re deciding on a suitable paper-based box type for your brand.

You can view your options right from our Products page. We also customize packaging based on your existing design. Still don’t have a design? No problem. We have seasoned in-house designers and packaging specialists who can walk you through the creation process. They can help you develop a custom box that will suit your product’s supply chain journey, brand identity, and budget. Contact us today to discuss your cardboard or corrugated carton box idea with our team.

The post Cardboard vs. Corrugated Carton Boxes: A Definitive Guide appeared first on Refine Packaging.

Nevertheless, there may be times when unquestionable damage occurs during shipping or when your products leave the warehouse. In fact, one out of 10 packages in the US arrive damaged at consumers’ doorsteps. Although some incidents may result from your courier or fulfillment partner’s negligence, you’re still responsible for retrieving the product and issuing a replacement or refund.

Yes, returns are inevitable. But you can take steps to prevent legitimate and fraudulent cases from hurting your bottom line. This article discusses how you can ensure the safe delivery of your fragile products.

Fragile Goods Defined

Fragility can mean different things to different sellers. But in general, fragile items require extra care and attention when shipping. These goods may be breakable such as glass, crystal, and ceramic. They also include objects with many curves, small delicate pieces that can bend or come off, and parts that can sustain scratches, tears, or dents when not packed well. Examples include electronic gadgets, musical instruments, artwork, furniture, and plants. Notebooks with wire binders, leather items that can be scuffed, and books with high-gloss covers that can have scratches can also be counted as fragile.                                                                

Common Causes of Shipping Damage

A study showed that 81% of ecommerce returns are due to product damage. Let’s look at all the factors that can cause damage to your fragile items, from inadequate or improper packing to external elements.

Improper packaging

Oversized box

Your products can bounce up and down or shift from side to side during land travel if your box is too big for your item. Your item’s body or edges may crush against each other or other packages if the box is too spacious and doesn’t contain enough infill that suits the product’s fragility, size, and quantity.

Weak material

Your box should be thick enough that it won’t collapse under your product’s weight. The packaging should stay intact throughout its journey to your customer. Lower-quality material can put your item at higher risk if your padding is already skimpy.

Absence of labels

Labels saying “Fragile,” “Hazardous,” or “Perishable” help alert delivery handlers about the nature of your package and how they should handle it.

Rough handling

Your package will go through several warehousing and shipping staff hands before reaching its destination. They may not always gingerly handle boxes or position them securely in their vehicles the way you expect them despite the labels you put on them.

Improper storage

Items containing food and perishable goods may rot or change in quality if you fail to keep them in temperature-controlled, infestation-free storage.

Climate and bad weather

Besides varied weather from state to state, we live in a time of sudden environmental changes. Climate and durability testing your packaging will be a good idea if you have a temperature-sensitive, breakable product.

Poor transit route choice

Like bad weather, choosing high-traffic routes for ground shipping may delay your delivery. Ask your fulfillment center about your options to address this concern.

Theft and tampering

Choose tamper-proof packaging and apply for insurance to ship high-value products safely. 

6 Steps to Ship Fragile Items Safely

1. Choose a box based on your item’s size and weight

We can borrow UPS Guidelines for packaging fragile goods: provide at least two inches of space between the box’s walls and the item inside. The right-sized box should also support your product’s weight and fit the necessary cushioning material.

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Heavy-duty materials may cost more, but consider the additional expense you’ll spend for possible return or replacement if you use a lower-priced but thinner and flimsier packaging that tears or deforms by just the touch of sweaty hands.

High-value items may require double-boxing (package within a package) for extra protection. This technique can also apply to large products—you can disassemble the parts and pack each into smaller boxes to spread the weight evenly in a larger box. However, this will naturally increase your shipping costs.

2. Wrap the item and surround it with infill

Wrap each product with paper and seal with Scotch tape followed by bubble wrap, ensuring you cover all the parts. Use packing tape to secure your plastic wrapping. Think twice before adding a second bubble layer, as it might make unboxing harder. It might be better to wrap your product in foam first instead of paper. If you’re shipping several items in a box, wrap them separately.

Fill the base of your box with crinkle paper, packing nuts, or other internal packaging before placing your product in the center. Then pour more infill around the item to restrict movement. Add corrugated inserts or craft paper on the box walls to make them sturdier. Give your box a slight shake to check if your item or items don’t shift. Pour a final infill layer—just enough to close the top flaps shut without a bulge.

You can follow the packing tips below for each fragile item category.

Ceramics and glassware

• Use thick packing paper or bubble wrap to wrap products individually. The bubbles should face inward to maximize cushioning.
• For cups and vases, fill the inside with crumpled paper or small bubble wrap pieces to prevent them from cracking from within.
• Stack plates vertically, not on their sides or edges. Put packing paper or bubble wrap between each individually wrapped plate and place them in a sturdy box.

Mirrors and artwork

• Use a box slightly bigger than your wrapped item to give room for cushioning material.
• For large artworks and mirrors, create a custom-sized hardboard or plywood cover to place over the front of the item for puncture and pressure protection.
• Attach cardboard or foam corner protectors to keep vulnerable portions from dents or scratches.
• Place the item in the center of the box to reduce direct contact from its edges, which are prone to external impact.
• Slide a framed mirror or artwork into its box vertically, the same way you would put a book on a shelf.
• For shipments with several pieces inside, always position the heaviest item at the bottom and the more delicate or lighter products on top to prevent damage from compression and distribute weight evenly.

Electronics

• Use the original packaging of the electronic product as much as possible—they’re designed to protect the item while in transit. If that’s unavailable, choose anti-static bubble wrap or bags when packing sensitive electronic components (like circuit boards and computer parts) to protect items from damage due to static electricity.
• Attach corner protectors or foam inserts for added support to gaming consoles, monitors, and other oddly shaped electronics.
• Wrap loose accessories and cables individually before placing them in a separate box or bag. Doing so prevents them from scratching or damaging the main product.
• Remove batteries from gadgets to prevent the possibility of leaks and damage.

3. Seal the box well and place safety markers

Once you close the box, tape it securely—several times if necessary. Couriers recommend the H-taping method. Before filling the box base with padding, fold down the bottom flaps—the smaller flaps go in first before the larger flaps—and tape down the middle of the box. 

For square boxes, fold two opposing flaps in, then the remaining two. Leave an overhang of tape on each end so the tape’s edge sticks to the side of the box for a secure seal. Apply pressure to ensure the tape adheres to the box.

Next, tape the opposite edges to form the letter H. Apply half of the tape on top of the box and the other half on the side. Repeat this method to seal the top of the box once you’ve put your products and fillers inside.

Apply “fragile” labels or stickers and other markings or instructions on how to store the package.

4. Add impact detectors or shock and tilt sensors

These tamper-proof detectors or sensors heighten awareness for handlers to keep boxes upright. These visual reminders typically turn red after tilting or excessive impact. 

Such sensor labels force couriers to be careful because the red marking becomes permanent, indicating mishandling. Due to their high price, these sensors are only advisable for highly delicate products.

5. Get shipping insurance

Couriers and third-party insurance providers offer shipping insurance. This fee covers damages or losses during your package’s transit.

Shipping or freight insurance differs from liability coverage, which covers only a specific dollar amount for every pound of your package’s weight. Coverage also varies among couriers and depends on your product’s commodity type and size.

In liability coverage, you must file a claim proving the carrier’s negligence and wait for processing, which can take several months. Under liability limits, the shipping firm can’t be responsible for damage or loss due to the shipper’s improper packaging, natural disaster or bad weather, government action, such as road closures, trade embargoes, or quarantines, and war.

When the carrier accepts your claim, it won’t pay for the item’s retail selling price—only the manufacturing cost or whatever its policy states.

Meanwhile, insurance providers will only ask you to declare that damage or loss occurred but won’t require you to supply proof of negligence. It’s more costly, but you can receive payment for claims within 30 days.

6.   Keep your return policy updated

Verify if the information about returning broken or damaged products is still accurate. Confirm whether you’ll apply your terms during the holidays or other events.

To prevent return fraud or abuse, ensure your policy requires the following:

• Duration: Number of days for filing returns.
• Set a limit for the return window: This will range based on the type of product, but is typically 30 days.
• Proof of purchase: Maintain paper receipts, confirmation codes, and emails to ensure claims aren’t for stolen goods. 
• Proof of damage: Your policy can also include submitting videos or images for proof of damage.
• Original packaging: Unique boxes can help to deter claims from “wardrobers” who return purchases after using them, as well as swappers.
• Valid ID: Including a photo that matches the buyer’s name to verify identity
• Quality assurance check: You can arrange for the shipping provider to perform a quality check at your customer’s doorstep on your behalf. Let your policy state that you will refuse returns that fail your parameters (incorrect product, used appearance, lack of supporting documents, such as tags, labels, and others).
• Penalties: If the number of fraudulent returns has become unmanageable, require customers to shoulder the costs of returns. You can also include a clause in your policy that your business “reserves the right to limit returns or exchanges in all instances.”

Another way to reduce returns is to provide sizing guides, 360-degree product views, access to customer reviews, and other content to help consumers grasp the look and feel of products better.

Moreover, keep track of feedback. Discover common complaints so you can make necessary adjustments to your product or offer.

How Top Couriers Treat Fragile Items

UPS

UPS charges $10.85 per package for “additional handling” or special handling of packages weighing over 70 pounds or any package if its longest side exceeds 48 inches and its second-longest is over 30 inches. The company also offers boxes and packaging services through The UPS Store.

UPS recommends limiting breakable contents per box to six to nine items, each weighing five pounds or less. It also advises shippers to stick a shipping label inside the parcel and outside the box.

FedEx

FedEx Express Package and Ground Services apply surcharges for large packages (the longest and second-longest sides are similar to UPS) weighing over 50 pounds for local shipment and over 70 pounds for overseas delivery. The rate depends on the company’s zoning system.

FedEx’s packing guide for fragile items suggests double-boxing sensitive products with three-inch padding inside and around a smaller box. Moreover, it offers cold shipping solutions for a fee.

USPS

In 2022, USPS stopped offering its “Label 875” option for special handling of fragile shipments, saying customers must pack carefully and purchase insurance. America’s national postal office offers up to $100 worth of insurance for Priority Mail and Priority Mail Express.

3 Ways to Test Your Packaging’s Performance

Packaging testing ensures that your product will be in good condition when it reaches your customer. Various tests are available to help you determine if your cushioning material and boxes can keep your product free from damage and degradation while on the way to its destination. Here are some ways to test your box’s durability:

1. Send a few products to people you trust

Are you just starting your business? Try shipping your products to relatives and friends. Then ask the recipients to send you images of the shipped item to help you see their condition.

2. Perform an improvised drop test

Pack your item the way you plan to do it for actual shipping. Then do any of the following: push it to the table’s edge until it drops. Or toss it in the air and let it fall to the ground. Put a heavy box or two on top of it. Then open your package to see whether or not your item sustained damage.

3. Bring it to a certified testing center

Although more costly, testing your materials at International Safe Transit Association (ISTA)-certified labs can give you peace of mind about your box and internal packaging choice. 

These facilities conduct drop, vibration, and compression tests to simulate different situations like products falling off a shelf or traveling on a bumpy road.

Impact of Damaged Goods on Business

Reexamining your packaging strategy for fragile items can help you avoid the following consequences when customers receive damaged products:

Returns

Goods returned to American online retailers reached $212 billion or 16% of the $1.29 trillion the sector earned in 2022. The highest expenses reportedly came from warehouse and equipment charges.

Losses

The cost involved in managing product returns could reach up to 17% of the item’s prime cost or all the expenses that go into producing it, including materials and labor. Other expenses include storage and disposal costs or repair fees for cosmetic damage. This means you get a lower profit from the repaired product.

You also risk losing future business because the shopper may fear receiving another damaged product if they order from you again. 91% of customers go to other brands after one bad experience. In some serious cases—for example, damaged items that cause fire or physical harm—shoppers might file a lawsuit against your company.

Moreover, staff can lose productivity from attending to tracking return orders, repackaging, and shipping replacements.

Bad reviews

Feedback about damaged products posted on your website, official social channels, or review sites mars your credibility.

Detecting Fraud

While merchants and resellers must accept returns as a business reality, you can take the following steps to detect perpetrators of returns abuse and fraud:

1. Review your customer records

Practice thorough record-keeping and regularly audit your data to determine “serial returners.” Create a blocklist to decline returns from these shoppers. Anti-fraud protection software can do this for you automatically.

You may also opt to manually approve orders from suspicious buyers. Another alternative is to end cash refunds and instead offer like-for-like swaps.

2. Train employees to enforce your policy and spot fraud

Set and post guidelines on spotting red flags and how to respond to suspicious behavior. Make them ask the returner, “What didn’t you like about the product?” Fraudsters will give lame excuses for this question.

Or rehearse staff on how to handle tricky situations, such as clients who turn irate over a lost receipt. Also, keep employees updated about scams like gift card tampering. 

Promote Product Safety and Client Satisfaction

If your business involves delicate items, packing your fragile product with the appropriate material is the first step toward customer satisfaction and revenue growth.

Refine Packaging has a wide array of boxes for every industry. At the same time, our team can answer any questions you may have while we work with you to design a customized box for your brand. Contact us today to discuss the packaging solution that will give your fragile goods a winning edge.

The post Fragile Goods? How to Safely Ship Products (And Reduce Return Fraud) appeared first on Refine Packaging.

If so, it’s critical to understand the basic types of labels, materials, and finishes before working with a professional printer. 

Without further ado, let’s dig into the nitty gritty details of product labels, customization options, types of finishes, and so much more!

How Labeling Supports Custom Packaging

Labeling is a component of custom packaging that focuses on promoting and describing your product so buyers know what’s in store for them if they decide to purchase it. This table summarizes the significant role of printed labels in relation to your product’s packaging.

When to Use Printed Packaging vs Custom Labeling

Importance of Custom Label Printing

Product label printing supports your branding efforts in the following ways:

1. Customization

Your custom labels can feature all the content your buyer needs to know about your product. Once you’ve decided on what information and images to include in your label, you can work with a designer or your printer for its layout, shape, and sizing. You can also do it yourself, using an online design tool such as Adobe or Canva.

2. Product and Brand Recognition

A designer can help you come up with ideas that will pique your target market’s interest and make your product easy to distinguish from your competition. Meanwhile, professional printers ensure quality and consistency in the overall look of your custom labels.

When your product has several variants (i.e., flavors or scents), you can design labels that can make sorting easier for wholesalers, retailers, and buyers.

3. Trust Building

Brands can better convince consumers to pick their products if their labels honestly state their contents and benefits. According to research, 97% of beauty product shoppers seek this kind of transparency.

4. Legal Compliance

To comply with industry and government standards on health and safety, include warnings, health hazards, emergency solutions, and other lawfully required information on your personalized labels.

5. Tracking

You can design custom quality labels to help you track products from production to delivery to your distribution points. Bar codes and other stockkeeping unit identification are necessary aids in current warehousing and shipping systems. They’re also useful in the case of product recalls.

6. Marketing Promotions

Labels for products can also feature information such as discounts, coupons, or other special offers to increase your product’s appeal. 

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General Types of Custom Packaging Labels

Labels are made to adhere well to their product’s packaging. Here are the most popular types of printed labels today:

1. Pressure-Sensitive Labels

The most common of all custom labels, pressure-sensitive labels are applied on packaging by hand or machine. They’re made up of a facestock (more info on this later) with or without a top coat and an adhesive with a liner. The details of a label’s anatomy are found in the next section. For optimum adherence, brands and manufacturers consider the surface or material that the label will be attached to.

• Dry peel: Dry peel labels have semi-permanent adhesives. They’re often designed to serve as coupons that buyers can peel off and present to get discounts or to join a contest.
• Reseal: Resealable labels allow customers to seal them back into the product packaging to keep its remaining contents fresh before use or consumption.

2. Shrink Sleeves

Also referred to as a shrink wrap, these polymer plastic films cover entire containers. The film is exposed to heat from a handheld gun or passes through the heat tunnel of industrial label printers to make it fit tightly around the product. Many bottled beverages that need refrigeration have heat-shrink labels.

3. In-Mold Labels

These preprinted polypropylene (PP) labels are injected into a mold where the plastic packaging container is formed. Once the packaging takes shape, the label is already fused into the container. This makes these labels look like they’re part of the container instead of a separate stock placed on its surface. Some laundry detergent bottles and food tubs (yogurt and butter) use this type of labeling.

4. Die-Cut Labels

These labels are made for uniquely shaped containers. They use a die and a press to cut the custom shapes. 

5. Thermal and Thermal Transfer Labels

A warm printhead (direct thermal) or heated ribbons (thermal transfer) print words or graphics on the label material instead of ink. These individually cut custom labels are usually used for price tags, shipping, and bar coding. They have a short life span and are prone to change color when exposed to another heat source. 

The Anatomy of Personalized Labels

Pressure-sensitive labels for products mainly consist of these five parts:

1. Facestock

The facestock is the specialty paper, film, or fabric that contains the graphics and text. Being the main part of the label, it’s the layer where the ink is applied and onto which the top coat and adhesive are anchored. It gives your custom labels structure, shape, and size.

2. Ink

Various types of inks are used to print text, graphics, and photos on the facestock: fade-free UV inks, nearly odorless and affordable water-based inks, and durable solvents that don’t require a top coat. Meanwhile, you can use specialty inks for unique metallic and fluorescent effects.

3. Top Coat

Not all labels need top coats (uncoated), but they’re necessary for facestocks made of plastic film. Top coating helps the ink spread out and cling to these types of surfaces. Meanwhile, varnishes and laminates are examples of top coats for paper labels. Besides providing an aesthetic finishing touch to their surface, this layer protects the print on labels from fading due to moisture, sunlight, or rough handling.

4. Adhesive

The adhesive layer is what sticks to your product’s container or packaging using pressure or heat. Your choice of adhesive material will depend on your packaging material, its shape, the environmental conditions it will be subject to, and your desired level of permanence. 

Here are the four basic types of adhesives:

• Peelable: Labels with removable adhesives can be taken off the surface without leaving any residue or destroying the label itself, compared to permanent ones. But removable adhesives can permanently bond to a surface when they’ve stuck to a surface for an extended time or due to environmental exposure.
• Permanent: Permanent adhesives can stick to moist and rough surfaces. Taking them off will usually result in destroying the facestock. They’re recommended for flat surfaces.
• Semi-permanent: Also called repositionable adhesive, this type lets you peel off labels from their surface in the short-term for adjustment. They settle and harden once reapplied to their new position.
• Freezer: Custom labels with freezer adhesives stay put on the products or their packaging without peeling or cracking—even in below zero settings.

5. Liner

The liner protects your adhesive until it’s applied to a surface. It can be made from paper or film. 

Facestock Materials

Paper and film are the most common materials used for the facestock of custom labels.

Paper

As ink settles well on paper, text and images look very sharp on this surface. Compared to film stock, they’re available in different colors and textures and are more affordably priced.

Paper-based labels are most appropriate for dry and cool indoor applications as they can only handle limited exposure to moisture (water and oil), extreme temperatures, and abrasion. Paper labels are best used for non-perishable goods like canned food as well as household and beauty products like soap bars.

Some common paper facestock examples for labels include:

• White paper: White paper is made of high-quality paper that’s bright and opaque white. It can have a matte, semi-glossy, or glossy finish.
• Metallic paper: Metallic paper gives products a polished sheen. Some of the available colors include gold, rose gold, silver, bronze, and copper bronze.
• Recycled paper: This brown-colored paper stock can give products a vintage, rustic, or handcrafted look. Facestock of this type includes kraft and the black and velvety vellum labels.
• Estate 4: Estate 4 paper is the most durable of the paper stocks due to its “wet strength” or water resistance. It’s also colored white and has a subtle linear texture.

Film

Facestock made of plastic film are tear-free and can conform to the shape of curved or other oddly shaped containers. They’re long-lasting due to their oil and chemical resistance. Film stocks also hold up to spillage, condensation, sweating, and sun exposure. They often have permanent adhesives and can attach to textured surfaces and painted metals.

• Vinyl: Technically called polyvinyl chloride (PVC), these plastic stocks made of ethylene and chlorine have a slight flex and are dishwasher-safe. They can withstand extremely cold environments and can last for up to five years, based on the vinyl formulation. These labels work best on vehicle windows (static cling vinyl) and bumpers, sports equipment, outdoor marketing devices, and frozen food that has to stay in below-zero temperatures for long periods of time. They come in white and clear varieties.
• Polypropylene: Biaxially oriented polypropylene (BOPP) is slightly thinner than vinyl and works well on contoured containers as they can stretch horizontally or vertically (biaxial). They have a medium lifespan (six months to two years) compared to vinyl and polyester stocks. They’re advisable for labeling smaller refrigerated items, such as meat, sauces, dressings, cheese, jams, and beverages. They’re available in white, silver, and transparent versions.
• Polyester: Also known as polyethylene terephthalate (PET) and mylar, polyester facestock can last over 10 years, making it the most durable of all film stocks. They’re ideal for industrial use due to their chemical and moisture resistance. These materials remain intact in extreme temperatures and under UV exposure. They’re the most expensive of all three plastic stocks. Professional printers can offer to make these labels using white, clear, and metalized polyester.
• Squeezable film: This material is best for squeezable bottles and tubes, including lotion, sunscreen, toothpaste, and other beauty and health products.

Different Types of Finishing for Customized labels

Labels need the right finish or top coat to make them last and look good longer. Here are some of the most popular label finishes:

1. Varnishes

Varnishes coat facestocks in clear liquid, making labels smoother and more resistant to spills and scuffs. They cost less than UV coatings and laminates but have the least staying power. A glossy varnish can make image-heavy labels stand out, while a non-reflective matte varnish can produce a subdued but professional effect. You can use spot varnish to highlight specific elements on your custom labels like your logo, brand name, or graphics.

2. UV-Resistant Coatings

This type of finish involves applying a special liquid on a label’s facestock and then curing it in ultraviolet light. The coating later becomes a permanent sunscreen that prevents your text, design, and colors from fading and other possible damage. 

Although this is usually a glossy finish, UV coating is also available in semi-gloss and matte. You have the option to cover the entire surface of your label (overcoat) or just selected sections (spot coat).

3. Laminates

Laminates are a thick film-like coating. They offer the greatest protection against sunlight, moisture, and abrasion. A glossy laminate sharpens the content and color of the label’s facestock while a subtle matte finish can give your custom labels an elegant touch.

4. Foils

A hot foil is composed of metalized PET film with heat and pressure-activated adhesive, which sticks well on glass bottles and cans. Hot foil can give a sophisticated look to custom wine labels. Meanwhile, a cold foil uses UV-curable adhesive, so it’s suited for thinner packaging material like plastic that can’t withstand high temperature. 

Finishing Formats: Roll, Sheet, and Fan-Folded

You can order custom-made product labels by sheets or rolls. Let’s see when to best use each of them.

1. Sheet Labels

When it comes to label sticker printing, sheet labels come in sheets of different paper sizes, although the most common is the A4 size.

Using sheet labels is the best option for short runs or smaller quantities (below 250 labels), including testing out the packaging of your new product or selling seasonal products. But some professional services can also offer this type of printing for a larger project.

2. Roll Labels

Roll labels are spun on a cardboard spool and get printed on using a roll printer. They’re advisable for bulk orders, including those that need specialty ink printing. They can be die-cut in any shape and size. Custom roll labels also work best for labels containing unique content per piece, such as bar codes or shipping labels.

3. Fan-Folded Labels

These pressure-sensitive custom labels are on a continuous backing sheet that folds along its perforations accordion style. This self-stacking format makes a great alternative to the roll format for shipping, address, and barcode labels.

Designing Your Own Labels

How do you come up with a label that will attract customers to choose your product? Here are some pointers.

1. Know Your Target Market and Existing Buyers

What’s your target demographic? It’s important to establish who your buyers are when designing your custom labels—and even your stickers and decals, for that matter. Determine their ages, gender, location, lifestyle, educational levels, income, values, and pain points or challenges that your product can solve. Listen to relevant feedback so you can personalize their experiences. Personalization is generally the difference between successful and disappointing campaigns.

Some relevant statistics to keep in mind:

• 56% of consumers become followers of a brand that “gets them” or understands their needs, and 89% choose to patronize a brand that shares their values.
• 64% of food shoppers spent more on products whose labels contained popular phrases such as “fresh,” “no sugar added,” “whole grain,” or “organic.”

2. Research the Competition

Examine and compare the attributes of your competitors’ marketing and branding materials, such as labels, flyers, stickers, and packaging. Take a close look at the color, typography, imagery, size, shape, and target demographic. What do consumers like and dislike about your competitors’ labels? What colors or other design elements are they drawn to? What are the major differences between your labels and theirs?

Take note of those elements that work well and brainstorm ways you can customize and improve them. Your custom labels should command attention when displayed side by side with similar products in-store. For e-commerce items, check if your labels will register well on the camera for photography and video shoots. You can also create custom shipping labels to elevate the look of plain cardboard packaging.

3. Determine the Essential Product Information to Include

Decide Your Information Hierarchy 

List down all the product details that you want your buyers to read on your label. Afterward, arrange them according to importance with the product name and brand name on top. For instance, in a food product, your brand’s logo, product’s weight, and other graphics should go in front. Meanwhile, instructions, expiry date, company’s contact information, and others can appear at the back.

In the image below, the brand’s logo, which includes its brand name and tagline, is on top of the label. The product’s name appears just below the brand’s logo. Its ingredients are listed in a smaller font and occupy the lower half of the label. The product’s net weight and storage instructions are printed at the bottom of the label, in a much smaller-sized font.

Meanwhile, this product’s back-of-pack label includes directions on how to prepare its contents. The company’s contact information, its country of origin, and bar code also appear there.

Highlight Your Unique Selling Point

Why would a customer want to buy your product instead of another brand? Research and create a profile of your leading competitors. See what your competitive advantage is over them so you can incorporate it in your selling point.

You also need to know what your target market needs and wants. Run a survey using your social channels or email questionnaires. Find out what your consumers’ pain points are and how your brand can help overcome them. After analyzing their feedback, you’ll be able to go beyond enumerating your product’s features or what it can offer. You can tell your buyers how your product can meet their needs and wants.

Below, the brand cited the benefits of its iremia oil burner blend on its rear label.

Include Legally Required Content

Check what your national, local, and industry laws state about the mandatory information that a custom label should carry.

In the United States, the Federal Hazardous Substances Act requires household items like cosmetics, cleaning products, and art materials to have storage and safe handling instructions. Thus, custom labels should carry signal words such as “poison”, “caution”, or “danger” and steps for first-aid treatment.

Food and beverage manufacturers are required to disclose the nutritional value and ingredients used in their products on the packaging. According to an American Heart Association survey, a majority of food shoppers (59%) always read packaged food labels before buying the product for the first time. The U.S. Food and Drug Administration also expects manufacturers to list the allergens, additives, and other chemicals used. 

Many plastic and latex products, such as children’s toys with toy parts, should carry choking hazard warnings, according to the Consumer Safety Protection Commission.

Use Customer-Friendly Language

Again, knowing your target customers is important here. You can review social media comments and feedback to pick out the phrases they commonly use. Also, use the results of your surveys and questionnaires to know what words resonate with them.

Besides using easy-to-understand language, be honest about what your product contains. In the latest Innova Consumer Survey, transparency emerged as the top need among food shoppers. This means including the ingredients list in plain English, certifications, and in-depth nutritional information.

Provide Space for Your Barcode

Barcodes are now necessary in helping you keep track of your products, whether inside the warehouse or the store. Aside from shipping and inventory purposes, they also protect your products and brand from counterfeiters. You can also use barcodes for promotions to reward consumers and build loyalty.

4. Consider the Packaging Materials

There are several factors to think about when deciding on the type of material to use for your individually cut labels. The label material refers to the facestock or that which receives the printed text, image, and barcode.

Shipping Container Size and What It’s Made Of

Will you be sticking the label on cardboard boxes or glass, can, or plastic shipping containers? Does it have a solid color or is it transparent? And how large (or small) is it? You need to measure the surface onto which you will apply your label so you can get the right fit and pick the correct adhesive.

Printing and Finish

Pick a material that carries your preferred texture—matte or glossy—and can take the kind of coating or finish that you want it to have such as hot stamping, embossing, debossing, and others.

Environmental Factors

Your chosen material should stay durable throughout your product’s lifespan. What kind of environment will it be exposed to? UV light can fade out inks, while water exposure can cause the ink to smear or get washed off the label.

Products that are subject to extreme cold such as refrigerated food may need freezer-grade adhesives. Meanwhile, others that are exposed to heat, such as products you take with you outdoors, are prone to peel (label lift). Special equipment can remove condensation to prevent this problem or adhesives should be allowed to fully set 24 hours after application.

Some custom labels may need foam or tape to reduce friction, while labels placed on wearables may need skin-friendly applications to endure stretching and sweat.

5. Select Your Colors and Fonts

Amid the possibilities, it’s best to stick with your core brand colors to strengthen your brand’s identity and reduce the chance of counterfeiting. Also, it’s best to refer to the Pantone Matching System to determine how your brand colors will register on preferred label materials.

Color

Colors are typically associated with certain emotional or psychological responses:

• Green: Green symbolizes growth, a fresh start, health, nature, peace, and wealth. Its darker shades can imply wisdom and prosperity. It’s used by brands that are into organic food and pro-environment products. Some investment firms also use green as it stands for the color of money. Goes well with: blue, yellow.
• Blue: Like green, blue can evoke a sense of tranquility and openness. Many banks and communications firms use this color as it embodies intelligence, security, and reliability. It’s also found in many home cleaning products as it conveys a sense of tranquility and openness. Goes well with: green, yellow, red, and orange.
• Red: Red exudes excitement, warmth, and strength. Brighter shades can stand for high energy while burgundy, maroon, and darker shades can represent elegance. Many food and beverage brands include this color in their packaging. Goes well with: yellow, black, blue, white, and green.
• Orange: Orange also radiates vitality and a sense of adventure but by a notch or so lower than red. It’s also linked to confidence, creativity, friendliness, and innovation. Innovators, technology, sports, recreation, and home improvement brands carry this color. Goes well with: blue, black, and white.
• Yellow: Yellow stands for joy, clarity, optimism, and youth. It’s recommended for children’s products, bath and body items, candle brands, and honey distributors. But it’s also ideal for warning labels and products containing powerful chemicals. Goes well with: red, blue, and black.
• Purple: Purple suggests nobility, luxury, and ambition. It’s also associated with youth, creativity, and spirituality. Several creative startups have opted to use this color, and so have some beverage companies for their wine bottles. It’s also found on custom labels of some anti-aging and high-end skincare products. Goes well with: yellow, blue (when mixed with deep purple).
• Pink: Pink is the color of romance, softness, serenity, and fantasy. Many skincare and beauty business brands tap this color. Goes well with: blue (when combined with baby pink), black.
• Black: Black evokes power, sophistication, solemnity, or mystery. It’s a popular choice among liquor brands and candlemakers. Goes well with: white, yellow.
• White: White represents simplicity, cleanliness, and innocence. It can also stir up feelings of lightness or reverence for what’s supernatural or sacred. The color is a common preference among medicinal, health and beauty, and household brands. Goes well with nearly any color.
• Gray: Gray indicates neutrality, balance, and professionalism. Information and technology, architecture, and industrial circles favor this color. Goes well with: brown.
• Brown: Brown creates feelings of comfort and dependability. Organic products as well as tea, coffee, and chocolate brands include this in their brand colors. Goes well with: purple, gray.

As a general principle, the darker the hues, the more serious your message is compared to bright and fun shades.

Typography

Just like in color selection, the fonts you choose for your custom labels should resonate with your brand. There are mainly four basic types of fonts:

• Sans serif: These fonts don’t have “feet.” A few examples are Arial, Helvetica, Century Gothic, and Corbel.
• Serif: These traditional fonts have feet. Examples include Times New Roman, Garamond, Georgia, and Baskerville.
• Slab serif: Although not very popular, these fonts have thick and bold serifs like Rockwell, Memphis, and Soho.
• Script: Examples of these cursive or handwriting-like fonts are Freestyle Script, Lavanderia, and Yellowtail. The upper case of “Unreadable” script fonts like Precious and Shathika can be used as the first letters of paragraphs.
• Display: Inspired by handcrafted signs and calligraphy, display or decorative fonts are best used for headings instead of body copy. Algerian, Pinewood, and Monoton are examples of display fonts.

To ensure you pick the appropriate font for your product labels, it should:

• Reflect the qualities of your product and brand voice. You can select chunky and loud fonts for fun and affordable products. Meanwhile, clean, light, and delicate or formal-looking fonts are suitable for high-end products.
• Appeal to your target demographic
• Meet regulatory standards, clearly presenting product benefits and instructions
• Work well with your graphics

While you can choose between classic and more cursive fonts for your product names and front-of-the-package details, it’s best to use simple but legible fonts for the rest of the product information such as ingredients list and directions for use.

When you come across a font that you like while browsing the web, you can discover its name by using online font finder tools.

6. Use High-Resolution Images

When preparing artwork to use or submit to your label printing service provider, choose images with a resolution of at least 300 dots per inch. Avoid pulling images uploaded on a website as they’re usually low-resolution and will look blurred when printed.

7. Conduct a Test Survey

You can work with a market research firm to hold a label test survey so you can tweak or further customize its design or content, depending on the feedback, before launching a full custom label printing run.

Set Your Brand Apart with Stunning Custom Labels

The team of creatives at Refine Packaging can turn your design ideas into reality, creating beautiful customized labels that will delight your customers and build brand affinity, all at a reasonable price for your business.  

Contact us today for a free, no-obligation quote on your custom packaging needs. We’ll support you in creating personalized labels that convey your brand’s unique personality, have amazing social appeal, and protect your product no matter where it travels.

The post Custom Labels: Essential Guide on Types and Design for Printing appeared first on Refine Packaging.

Understanding Paper Weights

Paper weights help to identify the thickness or thinness of paper, and also reflects the durability for its use in packaging.

When we talk about paper weights, it’s important to note that just like many other methods of measuring, the U.S. method of determining paper weight is different from the rest of the world.

In the U.S., paper weight is determined by its manufacturing origin. The rest of the world, on the other hand, compares the weight of a single square unit of paper.

When you have the same type of paper from two different paper manufacturers – this measuring system becomes increasingly complex. Although both papers may be physically the same, the process used to make them might differ. 

Comparing Different Grades of Paper

Different grades of paper are determined by how the paper is going to be used. They include:

Opaque and Offset Uncoated Papers

Offset uncoated papers are a large volume commodity grade of paper.

This grade of paper is often used for archival purposes since the way it’s made makes it more alkaline as opposed to acidic, and that allows the paper to look newer, longer. Plus, the internal bonding between the components in the paper itself is very good and the paper itself is rather durable. 

Offset paper generally weighs anywhere from 50 lbs to 80 lbs and can be finished using a smooth finish, a vellum finish (which, despite its name, has a rough texture) or a patterned finish like linen.

Opaque paper has a similar weight but the pulp quality is better. Plus, true to its name, this type of paper has a higher opacity, which means it’s more difficult to see through.

The finishes for opaque paper include an elegant-looking satin finish, a more durable film coat, or a simple, protective thin coat.

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Writing Paper

Traditionally known as Correspondence Papers or Bond Papers, this paper is most commonly found nestled within your home or office printer and is typically used for corporate letters or even hand-written notes.

You can add a watermark to this type of paper or add cotton fibers to give it more strength and a classier feel.

Text and Cover Papers

There are premium uncoated papers known as text and cover papers that are great for things like report covers, brochures and business cards. These types of papers are great for presentations and can come in a wide range of finishes, colors and patterns. 

4 Popular Paper Grades Used in Packaging

When you see things like 100# and the various coated or uncoated types, it’s easy to get overwhelmed. But there is somewhat of a secret to understanding the grade of paper.

Simply put, the higher the paper’s GSM or PT Unit, the thicker the material. The thicker the material, the more durable it is and the more weight it can sustain.

When deciding on the best paperboard to use for your stock or custom packaging, here are the 4 the most common types of paper grades you’ll likely find: 

1. Clay Coated News Backboard (CCNB)

Clay coated news backboard, commonly known as CCNB cartons, are made from a mix of recycled newspapers, old corrugated containers and a mix of other types of paper.

CCNB is often the most cost-effective and affordable option for printing, however there are some drawbacks to be aware of.

This type of packaging, due to its nature and its makeup, can absorb a lot of water, so it’s best not to choose this option if you’re concerned about moisture affecting your product. Foldable carton packaging is most often made with this type of paper.

Among paper grades, it’s not exactly a fan favorite simply because the quality isn’t as high as other types of paper grades, the paper can’t hold much weight in terms of product and it’s more affected by moisture than other varieties. Still, if you need something quick, easy and affordable, it doesn’t get much easier than this.

This type of paper often houses things like pet food, detergent, or dry goods like noodles or beans. 

2. Folding Box Board (FBB)

Folding box board, or FBB, is crafted using a combination of chemicals and mechanical material and processes to create a pulp material that’s several layers thick which adds exceptional strength and durability. Because the chemical layer of this paper is bleached, it provides an exceptional canvas on which to create high quality prints. 

This type of material is stiffer when compared to other grades of paper, but it’s a great choice for many different types of products and is often used for food, cosmetics and even pharmaceutical products. 

3. Solid Bleached Sulfate Board (SBS)

Solid Bleached Sulfate or SBS, is the epitome of product packaging.

Similar to folding box board, with SBS, the fibers are first chemically pulped and then bleached. After this process, the bleached pulp formed into box shapes. 

Since both the inside and outside of the box have a white surface, it’s an excellent option for printing in and out. You can also use high quality specialty processes on this grade of packaging, like spot UV printing, embossing and debossing, hot foil stamping and much more. 

Understandably, this type of custom packaging is most popular with a variety of industries and can package everything from food to tobacco to personal care items and everything in between. 

4. Natural Kraft or Coated Unbleached Kraft (SUS or CUK)

Known as SUS or CUK, kraft packaging is made from 100% recycled materials, making it a great choice for environmentally-conscious companies who want to embrace a more eco-friendly packaging style.

It’s an excellent option for food packaging and its fantastic strength and tear-resistant design makes it just as hardy and resilient for heavy beverages, cosmetics and more. A thin layer of kaolin clay can be applied to make the surface support even higher quality printing. 

Get Started with the Right Paper Grade for Your Packaging Project 

It’s understandable to feel overwhelmed or confused about the different grades and weights of paper and which is best for your retail packaging, not to mention the different types of finishes, applications and specialty printing options you get with your specific paper or packaging choice.

But you don’t have to navigate the uncertainty of paper grades and weights on your own. Here at Refine Packaging, we make all things packaging our business so that you don’t have to. If you have questions, aren’t sure what options to choose or would like more information on the types and grades of paper available and the pros and cons of each, contact us today for a free no obligation quote.

No matter what type of product you want to protect, we have packaging that’s fully customizable and ready to present your product in the best possible light.

We’ll take the time to better understand your project and your vision for your product packaging design, and then help you create a look that’s durable, attractive and attention-getting, so that you can concentrate on marketing and selling, while leaving the packaging design and printing to us. 

The post 4 Most Popular Types of Paper Grades in Packaging appeared first on Refine Packaging.

Carton packaging is also commonly referred to as carton boxes, folding cartons, paperboard cartons and paperboard boxes.

The History of Folding Cartons: Who Invented Carton Packaging?

Foldable carton packaging was invented by Charles Henry Foyle in the late 1800s, an Englishman who created the product we know as the carton today. It was essentially a piece of paper that was cut in such a way that it could be folded into a custom box. Although incredibly innovative for its time, carton packaging still lacked a lot of the features we know and love today.

For example, although it could be folded into a box shape, the ends still needed to be held together tightly, so it was common to use tacks and strings to hold the carton boxes together. This was expensive, not to mention labor-intensive. What’s more, such boxes were difficult to produce, so carton packaging like this was usually only used for valuable luxury items like jewelry. 

Fortunately, carton packaging came into the limelight in 1879, when Robert Gair realized that his printing press could cut through the carton material and allow for mass production of carton packaging. Food and snack companies realized that the foldable boxes greatly extended the shelf life of their products, and were among the first to regularly use such materials. 

The first snack food company to adopt the use of carton packaging was the National Biscuit Company, better known today as Nabisco. 

How Is Carton Packaging Used Today? 

Today, carton packaging has found a reliable home among store shelves around the world. When deciding on your product’s box design and presentation, there are many reasons to consider using carton boxes, including: 

Eco-Friendly Packaging

In this day and age, consumers do their best to be responsible stewards of the planet. That means buying and using packaging made from recyclable materials like Kraft paper.

Cartons are made with more than 75% paper that comes from sustainable sources and is harvested using responsible practices. This means choosing carton packaging boxes for your product packaging needs is an eco-friendly choice that reflects well on your brand and your company. 

High Shelf Appeal

Beautiful packaging has what we call “high shelf appeal”.  Properly designed, structured carton boxes help solidify your brand in the consumer’s mind as one of quality and consistency. What’s more, they provide ample space to showcase your brand message.

Tell your story through your product packaging design, highlight the benefits of your product, present a promotion or even showcase your social responsibility endeavors by using eco-friendly packaging. The choices are endless! 

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Common Types of Carton Packaging Boxes

There are several distinctive types of carton packaging, each with its own benefits depending on your needs. Companies turn to high quality paperboard carton packaging to protect, store and showcase their food, beverage, cosmetics, supplements and so much more. Here are just a few of the many different types of carton packaging that are commonly used in retail packaging. 

Strength Packaging

Strength packaging offers solid, reliable structural design to help protect your product from being compressed. But don’t let its rigidity fool you, high strength packaging is still fully customizable and printable so you can feel free to unleash your creativity with this durable packaging. 

Foldable Cartons

The original and still one of the most popular types of carton packaging. Flexible enough to be folded by hand if you only have a few small batches, or process through high speed automation for larger numbers, foldable cartons can be completely customized and designed for all your promotional needs.

Multipacks

If you’re selling several of an item together, multipacks are an excellent way to keep each item secure and stable while protecting the entire lot in one complete package. Often used for things like canned goods, cereal, yogurt and other types of food. 

Hybrid Packaging

Hybrid packaging blends different features of different types of carton packaging to create a “best of both worlds” combination. 

Looking for more types of carton packaging? Read our ultimate guide to carton boxes for a deeper look into folding cartons.

Other Benefits Carton Packaging Offers

It’s worth noting that like any type of packaging, carton packaging offers an opportunity to increase the perceived value of the product inside.

Although we’re no longer tying up or tacking down our cartons, and they’re no longer reserved for jewelry or other expensive items, carton packages have nevertheless surged in popularity and continue to be popular today with some adjustments, such as being made with eco-friendly materials. 

What’s more, foldable carton packaging can be shaped into any type of design. It doesn’t necessarily have to be a box. This makes it a great way to add a unique flair or creativity to your product to set it apart from all of the other boxes out there. Taking advantage of the large printable area on carton boxes is a smart idea that is commonly used in cosmetic packaging design, and is a great way to showcase the benefits of your product.

Build Your Brand with Carton Packaging 

Read our comprehensive article about packaging terminology to help you get up to speed with industry jargon as you create your own custom boxes.

At Refine Packaging, we understand that not everyone is a packaging expert.

Packaging is our passion and we strive to create printed designs that are the perfect match for your product. Our staff of graphic artists spans a variety of styles, so even if you don’t have a design in mind, we can create something that perfectly encompasses and reflects your brand, your story and your message, as well as the things that set you apart from your competition.

We create memorable, beautiful and stylish packaging for a wide range of industries, products and businesses large and small. If you’re thinking of choosing paperboard boxes or you’re not sure what type of custom packaging is right for your specific needs, talk to us!

We have decades of combined experience and bring our detailed industry knowledge to work for you in a way that’s easy to understand and will get your product in the hands of consumers faster. 

We also offer a variety of styles and printing processes that can make your packaging look extraordinary. From UV coating to foil stamping or different types of glosses, there are a variety of factors you’ll want to consider when choosing the right type of packaging material and design for your specific needs. But that doesn’t mean you have to do it all alone! 

Now that you’ve read about carton packaging boxes in more detail, why not contact the printing and packaging experts at Refine Packaging for a free, no obligation estimate on your printing and packaging needs? 

Let’s work together to create a style that’s uniquely your own, with packaging that exceeds your expectations. 

The post What is Carton Packaging? Folding Carton Packaging Explained. appeared first on Refine Packaging.

Who Invented Corrugated Packaging?

Corrugated packaging as we know it goes back more than a century, born from the need to package and store goods for a longer period of time.

In 1856, Healey and Allen, two Englishmen, secured a patent for the first known use of corrugated paper. Using two fluted rolls, corrugated paper was fed through a hand-cranked machine, creating fluted paper lining that could be placed in hats.

But corrugated paper for hats is one thing, and corrugated packaging for transporting products is completely different. An American named Albert S. Jones is responsible for this combination, and was the first person known to use corrugated paper to wrap fragile items like bottles and other easily breakable goods in a similar way that corrugated packaging is used today. 

How is Corrugated Packaging Made? 

The process for creating corrugated packaging hasn’t changed much since its humble origins in the 1850s.

With corrugated packaging, two sheets of flat paper known as liners or linerboard, are glued to a corrugated inner material called fluting.

Together, these distinctive layers are stronger than they would be if they were used separately. If you look closely at corrugating packaging, you can see a type of weave pattern. This is what adds structure and stability to the packaging. 

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Different fluting can be used to make different sizes of arch in the material, creating an end result that is structurally superior to many other types of packaging and is a great option for products that need to be handled and packed carefully. 

Curious for more details? We dive deeper into the corrugated packaging process and different flute grades in our ultimate guide to corrugated packaging.

Why Use Corrugated Packaging? 

There are several reasons why you might consider using corrugated packaging as your product packaging of choice: 

• Stronger than Cardboard: Safe, sturdy and protective, corrugated boxes are stronger than cardboard, so you can feel confident that whatever you put inside will stay safe and sound. Corrugated packaging is also crush and pressure-resistant. 
• A Wide Range of Sizes: Corrugated packaging is available in a wide range of sizes. Although it’s strong, it’s also lightweight, making it a great fit for nearly any type of product that needs to be protected, but without the added weight. 
• Can Be Broken Down and Reused: Corrugated boxes can be broken down and stored easily or transported without affecting the structural integrity of the packaging. 
• Good for the Environment: The packaging material itself is made from recycled and renewable materials, such as Kraft, making them an eco-friendly packaging option that consumers will appreciate. 

Corrugated vs. Cardboard Packaging: What’s the Difference? 

With the incredible surge in online shopping (COVID19 notwithstanding), customers expect their packages to be delivered safe and sound, with the contents in good condition.

Packages that arrive damaged, crushed, or torn open leave a bad impression when unboxing. That’s why it’s so important to consider what level of strength and stability you need in your packaging.

Corrugated packaging and cardboard packaging are two of the most popular types of boxes, but it’s important to understand the difference between them so you can decide on the right balance of protection for the product inside. 

Cardboard Packaging

Cardboard, also known as carton packaging, is made from thick paper or paper pulp which is then crafted into small packages or even material to help bolster the structure of lesser materials so that the contents won’t lose their shape.

Cardboard is inexpensive and easy to use as part of most shipping strategies, but it also may need additional packing material to keep the contents safe from being crushed, or being damaged by the elements. 

Corrugated Cartons

These are made up of several layers of material that are stronger together than they would be on their own. An inside liner and an outside liner are filled in the middle with a fluted material that helps solidify and strengthen the entire piece.

Corrugated cartons perfectly balance strength and lightness of weight, so they’re perfect if you need to ship a variety of products carefully. In addition to their structural strength, they’re also resistant to moisture and sudden changes in temperature.

Of course, no container is fully impervious to being crushed or being exposed to rain, sleet or heat for a long period of time, but if you want the added confidence that your product will arrive securely, corrugated packaging is a great option. 

Learn more about folding cartons with our ultimate guide to carton packaging to better understand the differences between corrugated and cardboard.

When To Use Corrugated Packaging

Corrugated packaging is best for products that need to be transported from a warehouse, to a processing center and onto a delivery vehicle. With so many people and machines handling the package, it needs to withstand being shuffled, slid, tossed and even dropped. If you want to add in an extra barrier of protection, you can wrap the interior product with additional cushioning for added security and peace of mind. 

Corrugated boxes are also a great choice if you want full customization control over your packaging design. You get all of the benefits of a large design area like with cardboard, except the added strength and durability. Additional features like custom opening folds, flaps, die-cuts and embossing or debossing are just a few of the many options you can add to create a unique design without worrying that the process will mar the product within. 

If you’re selling food, corrugated packaging is a must. Not only is corrugated much more sustainable and hygienic, but with so many people turning to online grocery shopping and delivery, companies are choosing to insulate their corrugated packaging for even greater protection to help seal in the temperature, especially for perishable goods. 

Choose a Trusted Corrugated Packaging Box Manufacturer

Read our packaging terms guide to help you get up to speed with industry terminology as you create your own custom boxes.

At Refine Packaging, our decades of combined experience, coupled with our deep knowledge of the custom packaging process across a variety of industries allow us to provide you with full-service packaging design and printing services.

From choosing the right packaging material for your product, to designing a look that captivates your audience and elevates your brand, trust the professionals at Refine Packaging to deliver an end result that’s so powerful and so compelling, you’ll want to buy your own product!

If you’re interested in learning more about how corrugated packaging may be the right choice for your packaging and shipping and fulfillment needs, or you’d like to consult with us on crafting the perfect design to showcase your product, we’d be delighted to work with you.

Even if you’re not sure what type of packaging you need for your product, get in touch with us. Our experts will take the time to understand your vision and your needs and work with you to craft packaging that perfectly expresses all of those points in one artistic creation.

Contact us today to learn more about our extensive printing and packaging services and get a free, no obligation quote for all your custom packaging needs.

The post What is Corrugated Packaging? How Corrugated Packaging is Made & When to Print with Corrugated Material appeared first on Refine Packaging.

When you need your packaging or printed material to stand out, consider using varnish to add a pop of depth to your colors or to add a subtle appearance that reflects your brand.

But what is varnish, exactly? What are the different types of varnish coating? What type of varnish will be the best to use?

We’re happy you asked.

The 4 Most Common Types of Varnish for Printing 

In the printing world, there are many different types of varnish, and each type has specific effects that you’ll want to better understand in order to choose the right style for your custom packaging. 

Let’s start with the 4 most common types of varnish coating used in printing and packaging:

• Gloss: Gloss is often applied over the full surface or in specific areas of your printed packaging. It creates and enhances the contrast between color while adding depth and detail to the color. Colors look like they “pop out” more to the naked eye. However, a high gloss finish under direct lighting can reflect a high degree of the lighting, which can make the text harder to read. 
• Matte: Matte gives your packaging design a more subtle, soft appearance. Because matte varnish is a non-reflective service, packaging with a lot of text, or text that needs to be read from a distance is better served by using a matte varnish as opposed to gloss. However, it’s worth noting that the effect appears much softer than with gloss finish. If you need your packaging to stand out and be noticed, gloss is still a better option.
• Strike-through Matte: Using this technique, matte varnish and gloss varnish are both applied to different areas of the printed piece. The matte varnish is applied to all of the areas except where a more impactful glossy effect is needed. In this way, the matte varnish strikes through the glossy effect and lets it shine while giving the rest of the packaging the more softer look. It’s a great way to create distinction between both types of the packaging. 
• Satin:  A combination of matte and gloss to create a “best of both worlds” varnish that is soft, yet allows for greater resistance against fingerprints, smudges and scuffs. It looks as if no varnish has been applied, so you can still enjoy a subtle effect, while giving your packaging enhanced protection during shipping. 

The Advantages of Varnish in Packaging and Print

Varnish adds (literally) a layer of quality to the box design or your printed product. 

Not only does it protect against scuffs, fingerprints and smudges, it also increases the perceived value of the product. Varnish can be applied via spot finishing or in different processes that span the whole sheet. 

Varnish is also flexible in terms of how it can be applied, which can create some unique and intense looks. 

For instance, with wet trapping, varnish is applied to wet ink during the printing process to truly ensure that the two meld together to create a distinctive style. With dry trapping, the ink is dried first and then the varnish is added by the press as well when the packaging passes through it a second time. 

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The Disadvantages of Varnish in Packaging and Print 

If there’s one major disadvantage to varnish, it’s that it doesn’t offer the level of protection that other types of coatings like UV coating or aqueous coating (AQ) do. 

Varnish is also not exactly eco-friendly and needs to be applied carefully in order to prevent toxic byproducts from being released into the air. 

Consider how your varnish choice will impact your decisions related to soft touch coating or lamination, matte or gloss lamination and embossing or debossing.

A Variety of Effects and Styles for Varnish Coating

Varnish isn’t just divided by types, like satin and gloss, but also compromises different techniques as well.

For example, gloss UV coating is one of the most popular options, and is both protective and high-impact. If your custom boxes or packaging will be handled a lot, gloss UV coating adds a greater level of durability than other types of varnish. 

The UV in UV coating means that the liquid coating is applied and then cured with UV drying lamps. This makes the finished product very resistant to being rubbed or scratched. 

If you want to add an even greater level of sensory effect to your packaging, consider raised UV coating. This helps “volumize” the printed area or graphic by creating a raised area that not only sticks out more visually, but also in a tactile sense – you can feel the difference between the raised area and the non-raised area. Many DVD packages feature this type of printing where the characters or other noticeable area on the packaging is raised to invite touch. 

Another great way to add attention and focus to your packaging is through the use of a spot UV pattern. This means that only a certain area of the packaging, such as your logo, is glossy, and this is the part that reflects light and catches the eye.

Are Varnishes the Same as Laminates?

No, varnishes and laminates are not the same. 

That said, both laminates and varnishes are used to refer to the same process – where a protective layer is added to make a piece look more luxurious or softer. Both laminates and varnishes also protect your retail packaging from being damaged, but laminate protects more than varnish.

In many cases, especially if your product isn’t being handled a lot, varnish is a much more economical way to add a layer of basic protection to your product without investing in the higher cost of laminates. 

A Seemingly Endless Variety of Options and Techniques

With seemingly endless variations – from spot UV to high gloss coatings to a softer, more subtle matte that gives your product a more luxurious look, to velvet-like satin that adds a touch of softness and refinement – there’s a lot to consider. 

There’s a certain style that you want your packaging to project. Whether you want to convey the look of an elegant package that begs to be opened, or a high-impact, glossy, eye-catching piece that demands attention, every package has its audience and every audience has certain expectations in mind.

Adding to this, the fact that now, more than ever, packaging carries its own sense of brand loyalty-building through unboxings and streamings.

That means there’s no better time to entrust your packaging and printing to a leading custom packaging company that knows how to make your packaging deliver the best possible impression, no matter what you’re selling. 

From earthy, natural designs to sophisticated, classy looks, Refine Packaging has your needs covered with the very latest in proven printing techniques that truly bring your packaging to life.

Our guide to packaging definitions can help you get up to speed with industry terminology as you create your own custom boxes.

Make Jaw-Droppingly Good Packaging with Varnish

The best way to truly understand how the expert printers, packaging specialists and artists at Refine Packaging can help you is to give us a call or fill out our free, no obligation quote estimate form. Tell us more about your packaging, your product and your goals. We’ll take the time to carefully listen to your needs and formulate a plan of action to help you take the next steps with confidence.

In addition, even if you’re not sure of how you want your packaging to appear, or even if you don’t have a lot or design in mind, don’t worry! We have artists on staff that draw from a variety of styles and inspirations to create a look you’ll love. 

Using varnish as a way to finish your packaging is just one of the many processes we can employ to give your packaging an edge that helps make it more attractive among other products on the shelves. There are a variety of ways to add a touch of elegance, beauty, style and much more to the finished packaging to make it impactful and attention-getting.

Contact Refine Packaging today to learn more about the wide variety of options we can use to help make your product packaging look jaw-droppingly good and let our experts walk you through the process, as well as answer any questions you may have.

The post What is Varnish? How Varnish Is Used in Printing and Packaging appeared first on Refine Packaging.

Whether people choose to admit it or not, the truth is, first impressions matter. A lot. And you’ll never get a second chance to make a great first impression. 

Custom packaging is an incredible and cost-efficient way to not only impress your customers, but to leave a long lasting impact for your brand that leads to increased word of mouth, social sharing, brand loyalty and revenue.

Now, that’s the definition of custom packaging, but it really doesn’t describe why so many companies make the switch to go custom with their retail packaging. 

Custom packaging is so much more than printed cardboard or other material for your product. It’s a statement for your brand. A chance to build a physical connection with your customers. An opportunity to engage and delight people, while educating them about your company’s mission, values and product benefits.

Now let’s jump into the top 6 benefits that branded packaging can give your growing company.

1. Custom Packaging Is Your First Impression

Imagine it’s the first time you’re buying a product from a new company. 

The packaging arrives, and it’s like nothing you’ve ever seen before. It might be a custom box with the company logo, but it’s also somehow deeper than that. 

The packaging itself doesn’t feel like corrugated cardboard. It feels soft. Elegant. Refined. You can tell that it’s an upper tier product – before you even open the box. 

That’s the kind of first impression that brands want to make, and can make, when they have full control over the elements that go into their packaging.

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2. Custom Packaging Is a Marketing Tool for Your Brand

If you want to present your product as high-end, all-natural, mysterious or cheerful, you can do all that and more with custom packaging. 

Through a combination of the right colors and materials, as well as the positioning of different elements and different printing processes, the pieces all come together perfectly. Like a fantastic puzzle where the real prize is inside, but half of the fun is opening the package itself.

Your brand has a story to tell. Every brand wants to be meaningful and to connect with its customers in a way that makes the brand relevant and interesting to them. 

Custom packaging boxes are part of your brand’s personality. And in many cases, it’s as much a part of the branding itself as the product within. 

3. Custom Packaging Boxes Are An Experience

If you’ve ever watched an unboxing video on Youtube or Facebook, you already know how much of a role custom packaging with your logo plays as part of the user experience. 

It’s not just one user opening a package in front of their fans, friends or family. It’s also a social experience. Especially for ecommerce packaging, where your package is often the only physical item your customer touches and feels throughout the purchasing process. 

The person familiar with the brand is also introducing that brand, often for the first time, to others who are watching. This becomes their first experience with the brand as well.

This social component plants the seed that if the people watching these unboxing videos want to experience something incredible, they should consider purchasing the item. 

Who knew that a package could carry those kinds of exciting feelings and that kind of sensation? Packaging design and printing teams understand this, and work with you to get it right, so that your consumers can enjoy such an experience, time and time again. 

4. Custom Packaging Sets Your Products Apart

For some companies, their custom packaging boxes are as much a part of them as their logo or name, and it would be unthinkable not to include it. 

Everyone has likely seen or heard of the small blue Tiffany’s boxes, with their tell-tale color. Anyone around knows at a glance that it’s a Tiffany’s box. They’ve put so much into their packaging, it’s unmistakable. 

If you can imagine, their box and its coloring have become so iconic, they’ve nearly transformed their packaging design itself into a piece of jewelry. That’s right, you can buy a “Tiffany blue” box necklace. 

But this is just one of many examples. For instance, if you wanted to project your brand’s emphasis on being environmentally-friendly, you might incorporate packaging items that are recyclable or biodegradable. 

Custom packaging boxes can make that happen through a combination of color, print material, printing process and of course the packaging design itself. 

5. Custom Packaging With Your Logo Is Memorable 

In a world of standard, bland boxes, custom packaging design stands out. 

Whether through the use of spot UV printing to make colors pop, or through specialized debossing or embossing that grabs attention, there are lots of options that can be included with your packaging to make it look unique and different from all the “same” styles of products on shelves.

It’s worth noting that if your product will be positioned under direct lighting, that certain types of printing can take advantage of this and create a very attractive and unique display that catches the eye and gets noticed. 

Even if your packaging won’t be positioned this way, there are still a number of printing processes that can make it stand out on store shelves and stay protected against things that could detract from its appearance like smudges or scuffs. 

6. Custom Packaging Is Worth The Investment For Small Businesses 

Of course, custom packaging boxes with your logo are often more expensive than your standard stock packaging, but it’s not just for the largest companies in the world. 

Small businesses stand to gain from all that custom packaging has to offer, too. After all, custom boxes cost less than you probably think. 

From stylish print options to unique packaging textures to shapes and designs that protect as well as create a great impression – there are several benefits to choosing custom packaging. 

Good packaging truly elevates your brand and your product to another level. That alone makes it worth the incremental investment. 

Is Custom Packaging Right for You? 

Branded packaging and custom boxes have a lot of benefits going for it that truly put your product in a class all its own. But it’s worth noting that there are other points to keep in mind, such as the number of custom package prints you want and the cost associated with designing the different plates (for use in the printing process) and so on. 

The printing world, for all of the magic and wonder it can create, is still a complex one. And whether this is your first time getting your product packaging printed, or you’re looking for alternatives, we want to help.

As one of America’s largest wholesale custom packaging vendors, our team at Refine Packaging makes it our business to get to know your business. 

Who are your customers? What do they want from your product? What would you like your product to convey when they open the package? What do you want them to experience? All of these things are intertwined and matter just as much as the product itself. 

With that being said, it’s easy to feel overwhelmed at the sheer number of printing options out there for your custom packaging needs. What is a dieline? What’s RGB and CMYK? What is the Pantone Matching System (PMS)? What’s aqueous coating? We want to help you understand the many different options available to you while still staying within your budget. 

Contact us today for a free estimate on your custom packaging solutions and supplies. Learn more about our prices, packaging definitions, our process and how we can help you. We’ll take the time to get to know your unique needs, your product needs, and how we can help. 

From artists on-staff that are ready to help bring your artistic vision to life, to printing professionals that are ready to make your box design truly shine, we have the knowledge, experience and expertise to ensure that your custom packaging looks flawless from start to finish.

The post What is Custom Packaging? Top 6 Benefits of Branded Packaging appeared first on Refine Packaging.