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Box: Style Stock Dimensions Designing Printing Finishing Order Specs
Style Basic Corrugated Box
Tuck Top with Snap or 1-2-3 Bottom Box:
The four flaps that form the bottom panel are die cut. To set up, the user folds the largest bottom panel first, then the two end panels. When the remaining bottom panel is folded and pressure is applied near the center, the flap "snaps" into the slot created by other panels. The style is convenient for small-volume shippers who do not have automatic set-up equipment. Because the bottom is not fully sealed, it may not be suitable for heavy products. Basic Corrugated Box
Regular Slotted Container (RSC) Top
with Snap or 1-2-3 Bottom Box:
Same as the Snap or 1-2-3 Bottom Container with Tuck Top, replacing the tuck top configuration with Regular Slotted Container (RSC) style flaps. RSC style flaps have the same length, and the two outer flaps (normally the lengthwise flaps) are one-half the container's width, so that they meet at the center of the box when folded. Tuck Top Auto Bottom: The top flap of the box tucks in toward the front of the box. When this box "pops open" manually or by machine the box bottom automatically forms a locking bottom. This is accomplished in the bindery stage of production by selected flaps spot glued together on the carton folder/gluer machine. Tuck Top Reverse Tuck Bottom: Tuck top with reverse tuck bottom are commonly used on small boxes and platforms. The auto bottom feature can not be applied due to folding and gluing carton machine restrictions and final assembly product line machine restrictions. The top flap tucks towards the front of the box and the bottom flap tucks the reverse direction (towards the back of the box). Simplex Box: Simplex boxes: The sides inter-lock to form a simple box bottom and slightly larger box top. Assembly of this box is quick and commonly manually assembled. Ideal for kits with multiple pieces. Click topic to go to: Box: Style Stock Dimensions Dimensions Designing Printing Finishing
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Dimensions Box Dimensions are given in the sequence of length, width and depth. The dimensions of a box are described based on the opening of an assembled box, which can be located on the top or the side, depending on how it is filled. (Length) The longer of the two sides is considered the length, (Width) the shorter of the two sides is considered the width. (Depth) The side perpendicular to length and width is considered the depth of the box. Click topic to go to: Box: Style Stock Dimensions Dimensions Designing Printing Finishing
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Stock Material: General Use: Custom packaging for retail products including food products, sporting goods, toys, automotive accessories, hardware parts, cosmetic items, dental supplies and pharmaceutical items. Coated One Side Solid Bleached Sulphate (C1S SBS) folding box (carton) grade: This grade of board (substrate) has two coats of clay on the printed side and usually a light starch coating on the back side. This grade provides a good smooth printing surface and is used primarily for folding boxes (cartons) or advertising media. The board can be cold or hot melt glued. Coated Two Side Solid Bleached Sulphate (C2S SBS) folding box (carton) grade: This grade of board (substrate) has two coats of clay on the printed side and depending upon which mill it came from, will have either two coats of clay or a heavy single cost of clay on the back side. Both sides of the board with two coats of clay on each side will have similar appearances whereas the sheets with the heavy single clay coating on the backside may be slightly different in appearance. Advertising signs, folding boxes (cartons) or cards with printing on both sides are good end uses for this grade. E-Flute Grades: E-flute is a common insert board (substrate) used with C1S SBS boxes to give the box strength and support due to weight. Flutes come in several standard shapes or flute profiles (A, B, C, E, F, etc.). A-flute is the largest, B-flute is next, C-flute follows and is between A and B in size. E-flute is smaller than B and F-flute is smaller yet. In addition to these five most common profiles- both larger and smaller than those listed here- are being created for more specialized boards. This photo illustrates the usage of an E-flute liner inserted into a C1S SBS chipboard box (carton). This particular carton has a special brushed silver stock mounted (litho-label) to C1S SBS by the manufacturing paper mill. The brushed silver surface is prepared for print. Special inks are used to adhere to the surface. The final step is to laminate the sheet which seals in the print. The box (carton) is prepared for die cutting, hot spot glue and folding. Recovered Stock Material: WHITE CLAY COATED NEWSBOARD BACK (WCCNB): This stock is white on one side and commonly has different shades of newsboard back due to being made from 100% recovered paper, from paper mills, board converters and post-consumer sources. Double-coated to provide smooth white surface for packaging graphics. Other names: coated recycled board (CRB) and uncoated recycled board (URB). Click topic to go to: Box: Style Stock Dimensions Dimensions Designing Printing Finishing
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Graphic Designing Package functional requirements: to sell the product; as a container; as a sales tool- Consumers make purchasing decisions based partially on the appearance of a package. The finished package look is greatly affected by the material it is printed on. Coated 1 Side (C1S) Solid Bleached Sulphate Grades (SBS) and E-flute Grades are as important as its structural functions in many instances.
The package stores its contents, informs and sells the product. While the package engineer ensures that a box is functional as a container, the graphic designer is responsible for making the box function as a sales tool. Colors, images and text must be chosen with the potential end consumer in mind.
Package criteria: number of boxes; magnitude of investment; printing process- Depending on the sophistication of printing desired, how many boxes are needed and the magnitude of investment, the designer will recommend a printing process usually flexography or lithography printing.
Using desktop computer-aided design (CAD) and computer assisted manufacturing (CAM) software, the graphics designer creates a prototype of the package. CAD/CAM systems allow the designer to provide a precise representation of what the customer wants while meeting manufacturing standards.
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Printing Lithography and Flexography: After final approval of the structure and design of the box, images and text must be transferred to the board surface.
What to print on? Choose the best printing process for a certain project, decide which material to print on- the board itself, a separate sheet of paper which will be glued to the board (known as litho labeling). Some printing process dictate the material used. Decisions are made with economics, scheduling and quality factors in mind. Printing projects must be matched with individual printing methods in order to control costs and achieve the highest possible quality. Each method of printing has its own set of advantages and disadvantages.
Lithography: This type of printing is possible on a wide range of surface textures. The plates carry very sharp images and precise dots, and the printing process is fast because the plates are easy to make, change and set up. Offset lithography is cost-efficient. The inked image is transferred (or offset) from the plate to a rubber cylinder and then to the substrate (board surface).
Single Face Lamination: Laminating a prepared top-sheet directly to E-flute is another option for obtaining lithography quality graphics on containers. White-coated or solid-bleached top sheets are lithography printed and then laminated directly to the E-flute. In addition to the excellent graphics, an advantage to this process includes excellent cut-to-print registration.
Litho-Labeling Board: Litho-Labeling, the process of lithography printing onto a sheet of paper or label stock which is later glued to the board, results in high quality images.
Flexography: Printing direct from the plate to the surface, is performed commonly on flute constructed board after it is manufactured and cut into sheets. It is typically the least expensive way to print but a lower quality, loose cut-to-print registration and difficult to hold finer details. Flexography uses flexible rubber or polymer plates to transfer images. It uses raised images on a plate, but the plate has a "kiss" impression on the substrate (board surface). The print quality depends on many variables in the flexography process. It easily prints on rough materials but is influenced by the absorbency of the stock. It is a lower quality print process. Other types of printing such as letterpress, screen printing and digital printing are not covered here.
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Finishing (Coatings & Treatments) Many coatings and treatments can be applied to boxes to give them the qualities that board alone does not have. Each coating or treatment must be evaluated for its effectiveness and its effect on the contents of the boxes and the box manufacturing process. Consider the treated box's printability, heat resistance factor, water resistance factor, whether or not it is appropriate for food contact per FDA and its ability to take cold-set or hot-set glue. A few of the major functions of coatings and treatments are: water and moisture resistance, oil and grease resistance, and abrasion resistance.
Water & Moisture Resistance: Water and moisture penetration might weaken a box or affect its contents. Film lamination (most often poly-ethyline) or aqueous-based treatments can be used on the surface of the box to resist water and moisture penetration.
Box Title: Name of Product
Common uses for C1S SBS
8 pt. Business Cards
18 pt. Boxes- small lightweight contents
E-flute liner gives great strength to a 18 pt. box (more than 24 pt.)
20 pt. Boxes- small lightweight contents
22 pt. Boxes- larger heavier weight contents
24 pt. Boxes- larger heavier weight contents
This "BOX" information is part of the Press Proof Resource Guide located under the Production Procedures tab. Contact your Press Proof Print Specialist for a Resource Guide password or CD. For additional information about Press Proof visit the web site "www.pressproof.com"