Sarcina Packaging: Bespoke Paper-Based Packaging

Origination or printing plate costs are the costs associated with producing the printing plates that impartthe ink to create the finisheditems. In recent years add on charges for lithographic printing plates have all but been abolished –and we certainly don't charge extra for them.

Flexographic printing plates-mainly used in the production of flexo printed corrugate boxes and labels arehowever chargeable. Mainly because unlike litho plates'flexo plates are more costly to produce and can be used for subsequent production runs. The cost of the plates will depend on the size and the complexity of the print. As a rule,the more detail within the print the more they tend to cost. Flexo plates are also costed per colour per side. As such it's a sensible idea to try and future proof your artwork in thiscase to maximise the longevity of the plate.

There are no origination costs associated with digital printing.

A die forme is the toolthat cuts the board into the desiredshape. Mostcommonly used in a flat bed format it comprisesaflat base, usually made of wood, with blades or rules embedded into it. The blades –that can either cut or crease the board -mirror the shape and size of the finished packaging whichturnsa flat sheet of board into the desiredbox or carton.

The costs of the die forme needsto be factored into the budget as they are complex to make and are precision in nature. By definition,bespoke packaging results in a box or carton that is specifically designedto your demands. One of the costs of this tailored approach is that a die forme will need to be commissioned. The positive news is that these costs are one off and assuming the architecture of the box doesn't change, the forme can be used for future production runs.

The costs of the die forme will depend on the meterage of steel orrule used in its construction and its overall size. But typically they range for £220 -£500 plus VAT.

Prior to the bulk production of any box or carton, itis common to receive a plain CAD cut sample for size and style testing. These samples are produced on a Computer Aided Design table –a large format cutting table mounted with a digital cutter.

CAD samples are usually provided free of charge and are there to help reduce the riskof incorrect sizing or styles. The samples can be cut using the correct (or very close to) material and the architecture of the sample will exactly mirror the final production item.

CAD samples are provided plain withoutprint. For the printed elements of the packaging anonscreen PDF proof will be issued for approval. In some cases, for litho work, a wet or press proof can be providedbut in almost all cases this will come with additional charges.

As a rule,the time you should allocate for pre-productionproduct design, sampling and artwork checks should be as long or longer than the bulk productionitself. There is a general assumption that pre-production work can be completed very quickly. But the reality is that bespoke packaging is often an evolution of thinking. What you start offbelieving will be the solution is often not the case. Bespoke packaging with its minimum order volumes and set up costs (not always applicable) can be costly. Itis therefore important that sufficient time is given to ensuring that the end product is right for the contents within, for the brand, and for the end customer

We can help with all these elements –from initial brief, sampling, colour swatches and assistance and guidance with artwork.

The time it takes to produce your item will depend on the materials used, the volume required, the complexity of the itemand the time of the year. Quarter four is always the busiest within the packaging sector and lead timeswill nearly always push out in the run up to and immediately after Christmas.

Generally four weeks is theindustry standard to producebespoke packaging.At less busy times we may be able to improve upon this but equally this may push out during busier times. Itis always beneficial to plan your packaging requirements and where applicable a forward order schedule is a simple but effective way to mitigate against stock outages.

In all cases leadtimes fluctuate and are always stated as post all approvals. The advice is to always leave extra time for artworkamendments, structural changes and production proofing.