How A Rigid Gift Box Is Made - Complete Guide On Gift Box Making
Every product has its own packaging box. Making and manufacturing boxes is a tedious task. I know there are some people who may think that I will just tell you the sketch, specifications, materials and so on, and you will be able to print a batch for me right away.
In fact, a standard gift box requires a process that goes through a number of steps. Today, I will tell you about what steps a box production has to go through.
Not every box requires the same process. Some are easier to make, such as the lid and bottom rigid box, some are more complicated, like multi-drawer rigid boxes. But we can still find a general workflow for making a standard gift box.Here it is:
Plate-making --> paper selection (wrapping paper, gray board) --> printing process (pay attention to color differences and ink dots and other issues) --> surface treatment (UV, Spot UV, Lamination, Varnish, Foil stamping, and more) --> die-cutting of wraping paper--> die-cutting of gray board-->grooving & shaping of gray board--> laminating of wraping paper-->assembling-->inspection-->packing.
Plate-making
Plate making is to convert the graphic information in the computer into a medium that can be used for printing. Before printing, we need to finish the plate production, and then put the plate into the printing machine, in order to have a way to print what you want.
Paper Selection
More than 1 layer of paper material is used for a gift box . You need to consider the paper material for the wrapping paper and the gray board.
This paper is the first layer of a rigid gift box. The choice of wrapping paper is very important according to the customer's document design requirements and the effect to be reflected.These aspects are mainly considered when choosing the wrapping paper:
① the type of paper, such as whether to use coated paper, or art paper, pearlescent paper?
② The thickness of the paper. The paper can not be too thick, the surface might not be flat in such case; but the paper also can not be too thin, otherwise the desired effect can not be achieved.
③ Consider the possibility of the surface finishing.
A gray cardboard is a type of recycled paper. Its characteristics include single-gray, double-gray, full-gray and high-gloss, depending on customer needs on the surface flatness. It is the environmental protection packaging material, ranging from 250g ~ 10000g, thickness from 0.4mm ~ 20mm, thickness and quantitative quantity have no limit. We usually choose the appropriate specifications of the gray cardboard according to the size of the gift box specifications.
The printing process
Offset printing is currently the most mature printing process for color box printing. The printing is achieved by using the principle of ink repulsion. The advantages of offset printing are: easy to do, low cost, high production efficiency, exquisite patterns, and stable quality.
There are two main ways of offset printing for color boxes . One is to print directly on cardboard, and the other is to print the wrapping paper first, and then laminate the paper with gray board. This is the method used for a gift box.
Surface treatment
The surface finishing process, also called post- printing process plays a curial part for an eye-catching luxury gift box, There are many surface treatment options available on the market:
① Varnishing;
② Lamination (light film, matte film, tactile film, scratch-resistant film, etc.);
③ Hot stamping (gold, red gold, color gold, silver, laser, etc.);
④ UV oil or screen ink;
⑤ Special color powder;
⑥ Embossing;
⑦ Debossing, etc.
Customers usually combine 1or 2 finishing options to highlight the presence of a gift box.
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Die-cutting Process
In die-cutting, the pattern is combined into a die-cutting plate, under pressure, the printed material or other board-shaped blank is rolled and cut into the required shape and cut marks are formed. It is a very important part of the process, especially for gift packaging boxes, the technical requirements for die-cutting are higher, the precision and accuracy determine the quality of the product, a slight error directly affects the quality of subsequent processing.
For the gift box, we usually need to do the die-cutting for the surface paper and gray boards.
Slotting & Shaping of gray board
Slotting(or Grooving) is to cut V-slots on 1~4MM thick gray board with a grooving machine, generally retaining about 0.25MM connecting layer. V-slots are angled, generally 90 degrees, 120 degrees, or different angled V-slots according to the product structure.
Slotting is a key step in the production of gift boxes. Before the gray board card is formed, the gray board must be V-notched so that after the gray board card is bent, the outside is straight and the inside is square, the corners are well-defined and the four corners match precisely.
Laminating of wrapping paper
Lamination is a necessary process in the gift box process, which is based on the requirements of different products, the copper plate paper, art paper, velvet, leather material through the glue machine over glue or spray glue, and the gray board tightly stick together, so that the gray board surface gray appearance for a new look, not only beautify the appearance of the box, but also improve the added value of the ridid gift box.
Assembling
A complete gift box usually comes with add-on accessories such as handles, locks, user manual, and drying agents etc. So these parts will need to be assembled after the box is formed.
Inspection & Packing
A final inspection before packing is a must to ensure that everything is included in the package and no flawns have been found in each box. Most of the time, the customer will also ask a third party to verify the quality and quantity of the boxes, and then give a final sign that boxes are ready for shipping. Only in this case can we make the final packing.
Conclusion
Isn't it surprising? There are so many processes behind a single gift box, from the design of the pre-press structure, printing, to the post printing process . Every step is essential.
When choosing a packaging supplier, you need someone who is experienced in the whole gift box making process to save troubles.
Ketsana is here for you . We provide a full- turn luxury packaging solution for brand companies and factories including design, sampling, printing production, post-printing process, logistics.
We are your reliable packaging provider who aime to build up your brands. Think Packaging, Choose Ketsana.
Sophie
Ketsana Pack
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