Structure Basics

The Complexity of a Corrugated Cardboard Box

The humble container is more than meets the eye!

It’s easy to dismiss ink as just a commodity item of expediency that finishes off a creative project. That would be a mistake, though. Ink has dimensions that matter when it is part of your business. Just a few of those dimensions include:

Application of Ink

There are five primary methods for applying ink to packaging:

1. Direct Print – Flexographic print is applied directly to the corrugated board. Requires printing plates and large runs.
2. Preprint – The liner board is printed flexographically prior to being combined with the corrugated board.
3. Litho Labels – Graphics are printed using lithography onto paper and then laminated to corrugated board. Typically applied in spots, not full coverage
4. Litho-Lam – Graphics are printed on sheets using offset lithography then laminated directly to single-face corrugate board. High quality graphics covering the entire package. Requires printing plates and large runs.
5. Digital – CMYK ink is directly applied to the substrate. An economical alternative for low quantities and quick turnaround.

Ink Language

Traditional packaging methods such as Flexographic delivers the print with water-based inks, aqueous and UV varnishes and can match PMS color system. Lithographic printing uses solvent and soy based inks, aqueous and UV varnishes and can also match PMS systems. PMS and special matching color systems are the highest quality of color, but typically require very high production runs because they buy their ink “by the gallon”.

Digital printing uses CMYK UV and water-based inks. Digital printing is very economical as special ink isn’t purchased for specific jobs, but requires the color values to be converted to CMYK, resulting in less precision.

Coating versus Curing

It’s a matter of under versus over. A coated paper is a paper that has an application of clay to the blank paper causing it to be less porous. When the ink is then applied it “sits” on top of the paper and absorbs less of it. The effect can be brighter, more vivid colors and a glossy sheen. But coated papers, with their extra processes, also come with extra cost. A cured ink is a post ink application. It sets the ink and gives it a slight sheen, but not a gloss. The curing process protects it from mild weather and handling as well. A non-cured ink may rub off on your hands, like a newspaper.

Masking

Think of a mask as an “out-of-bounds” line. With custom-printed packaging, ink is one of the largest expenses, so it stands to reason that you will want to apply the ink to the areas that make an impact. Areas like the bottom of the box or the hidden interior flaps in many cases don’t bring as much value to the branding or messaging and eliminating them can save you money. There are situations where full color on the bottom or on the insides adds to the social media share-worthy aspects of the packaging. In these cases, the cost of the inside ink is an easy trade off with the organic reach received by the social media “unboxing” that stretches your marketing budget.

There are several factors to think about with ink. Each situation is different. Working with a company like BoxUp, you have the advantage of being able to test, run small quantities, and see what works for you.