The max grammage an offset press can handle is no more than 400gsm, which is around 0.50-0.55mm. Then how to get a 700gsm paperboard printed to get a very thick black paper box? Recently a client in UK asked us to make such a custom paper box for the coffee packaging. Beside the custom thickness, debossing and embossing finish are both used onto the box.
The black paper box has the custom thickness. The big Ue logo is embossed.
The F flute corrugated box is an option. The crisp full color printing of the F flute, E flute box is achieved through the litho laminating process in which a piece of 300gsm CCNB paperboard is glued onto the single faced corrugated board. But the fluting paper sometimes give some customers a sense of cheap quality, even though it is not always the truth. The corrugated box can high-end and luxury.
The 700gsm paperboard is around 0.7-0.8mm in thickness. No litho press can handle such a piece of thick paperboard. Screen silk printing is a solution, but it lacks accuracy and precision. Then how do we solve the problem?
The custom black box has the pantone white inks printing with the STE box style.
Here is the secret. The process is much the same as the litho laminating for the corrugated boxes. We have 2 piece of 350gsm black specialty paperboard and glue them together. Firstly, we do the litho printing on one piece of 350gsm black specialty paper, then we glue it to the other piece of the black specialty paperboard.
Besides the thickness of the box, the client has some other special requirement, debossing for the star patterns on the left side and right side panels of the box, embossing for the logo image on the front panel.
Debossing for the star patterns on the side panels of the box.
Other features of the coffee paper box includes the STE box structure, which is referred to as the straight tuck end paper box. For the color printing, it is the pantone white inks used.
Recently we made a sample box for an American client, which is a matte black color foldable rigid box. It is for the packaging of a very high-tech and innovative electronical product. The client likes this box style a lot because of the foldability of the box. It can be flat shipped to reduce the shipping cost and warehouse need due to the small volume.
The foldable rigid box has the matte black color printing and finish inside and out.
In order to increase the durability and strength of the box, usually 2mm greyboard/chipboard is used to create the box rigidity. And the grammage is around 1200-1300gsm. When extra rigidity is needed, the 2.5mm greyboard is used.
On the back of the top panel, the slogan text is PMS color printed. While on the outside the box, it has the very pretty line pattern and in the center is the company logo. On the front of the box is the brand name of the product.
Outside printing for the collapsible rigid box.
Actually, the black lines on the top can also be spot UV varnished to create a striking visual effect. Some of our clients would like us to put the stickers on the 4 corners of the box, then the box can be well set up. While some would like their customers to reuse the box without the stickers.
A lots of our client like this box because of its unique design. It is foldable to be flat shipped and stored and it makes the product looks high-end. However, the bad points of the collapsible rigid box is that a lot of hand work is involved during the box making procedures. This increases the final cost of the box, which makes the foldable rigid box much more expensive than the other common style rigid boxes.
Also there are size requirement for the box. The length of the box is supposed to be at least 2 times of the box height. If you would like us to make such a custom rigid box for you, you must pay attention to the size.
This article is a about a pink color printed rigid box with the lift off lid. We made this box for a client in USA. Unlike most detachable lid rigid boxes which has the same height for the top lid and bottom base. This box has the lid which is only 1/3 the height of the base box.
The height of the lid is much shorter than the base, which makes the printing on the base sides possible.
The lift off lid rigid box is also referred to the detachable lid box. Some people call it the lid and base box. Such boxes are easy to make but very efficient for the product packaging. The box consists of 2 categories. For one type of the box, the lid covers the whole body of the base and they have the same height. For the other type of the box, the lid only covers part of the base. Because less material is used, the later is usually cheaper.
Pink color printing inside and out for the lid and base rigid box
This box is nearly a cubic box which has the size 4*4*5″ for the base and 4*4*1.5″ for the lid. The box is also printed pink color inside and out the base and lid. It is made of the 2mm greyboard, which gives enough rigidity and strength to the box. For the printing and finish, it is CMYK full color printed and matte laminated. Actually, the text patterns can also be spot UV varnished to make a better box.
In general, the box has not the complicated finish and the design the simple, but looks very beautiful.