When a graphic needs completely cover the paper or surface area, it needs to bleed to the edge. A printer is unable to print completely to the edge of the paper, therefore to attain a true full bleed, an image must be printed on a larger sheet of paper and trimmed down. Bleed also refers to proper boundary of the graphic design. Pertinent information and important graphics should be kept away from the bleed boundary.
An extra piece of chipboard attached to the flap of a rigid box, usually a hinged cigar style box. The bonus board helps to keep the contents in place within the insert. This element is especially important in board game boxes in case the box is turned upside-down.
Refers to the empty space within a box, more often referring to the custom cavity created by a thermoformed plastic tray or die cut foam insert. The cavity holds everything from game pieces to flash drives. A precision-cut cavity holds products snugly since it is created to the product’s exact contours.
Also called rigid chipboard, this material is the missing link between corrugated cardboard and particleboard. While it is not made of wood, chipboard is made of compressed recycled materials, like cardboard. It has a grain, making one direction sturdier than the other. It comes in two colors: Kraft brown or News grey. White chipboard is coated in clay.
Cigar Style Box
One of the most timeless styles of custom box, this hinged presentation packaging opens like humidors of old with a top lid and an open cavity that can be filled with foam, plastic trays, or lined with a variety of textures. An elegant piece most associated with jewelry and other gifts, but can also be used for press kits and launch kits.
Closed Cell Foam
A dense foam packaging material created by trapping gas or air bubbles in polyethylene (PE). Closed cell refers to the pockets of gas that are not open, or exposed, to the air. A sturdier foam for firmly contouring to products of all shapes and sizes. Resistant to water moisture and vapor. Available in a variety of colors.
Corrugated fiberboard is a paper-based material consisting of a fluted corrugated sheet and one or two flat linerboards. It is widely used in the manufacture of corrugated boxes and shipping containers.
The instrument for shearing materials–foam, plastics, soft metals–for a precise, consistent cut. In packaging, the most common use for die cut materials is custom foam inserts. Die cutting custom foam cavities allows secure packaging for specific products as well as a sharp, professional presentation.
Debossing is the reverse of embossing. An image such as a logo, a title, or other design is heat-pressed into the surface of the paper with a heated die, creating depressions rather than raised impressions as in embossing.
Die Cut Foam
Custom foam can be die-cut to hold any size object safe and securely in a custom box. Foam is an excellent option for box packaging because it’s customized to keep your products safe as well as add a professional element that will reinforce your brand.
E-flute is a type of corrugated flute that is used as material for box packaging. E refers to the size of the flute as there is also A, B, & C flute. The difference between the types is the flute height. E-flute is the most popular size because the flute size is durable, printing turns out better, and because it’s smaller, it saves on storage space.
An eco box is a term to refer to a box that is customized to be environmentally friendly. An eco box can feature recycled content or be 100% recyclable. Eco boxes can also have VOC-free coatings and be printed with soy-based inks that are not harmful for the environment.
Embossing is an artistic technique which creates a raised pattern on a custom box to give your packaging a unique look and texture.
A flute is the wavy, rippled sheet that fits between two linerboards of a piece of corrugated fiberboard. Different flute sizes include A-flute, B-flute, C-flute, and E-flute.
Foil stamping is the application of pigment or metallic foil, often gold or silver, to paper where a heated die is stamped onto the foil, making it adhere to the surface leaving the design of the die on the paper.
Foil Stamping Die
Similar in procedure to a cutting die, a foil stamping die is a blunt stamp, usually heated, to apply a layer of foil to a box being embossed or debossed. These techniques create a distinctive, textured brand in packaging and foil stamping is an extra layer to create a metallic trim to the lettering or logo.
The process by which a specific product is paired with other items, such as pamphlets, souvenirs, compact discs, or flash drives, to turn a singular product into a boxed collection, or kit. This process can include the box design, graphics, custom inserts, data preloading, and finally boxing everything for shipment, so that the final product is ready to distribute on arrival.
Using a low-level laser to create patterns in malleable materials. Similar to laser printing, except that no ink is used and, instead of printing on the surface, the image is created by “cutting” away the material in a particular pattern by way of laser beam.
Offset printing is a method that uses a metal plate and rubber blanket to set ink upon a form of media. The ink is applied one color at a time where it sticks to specific areas. The printers are either sheet fed or web fed. Offset printing provides a consistent high quality image and is an option Sunrise Packaging offers for many of our products.
Open Cell Foam
The opposite of closed cell foam, in which the pockets created in the polyethylene are open and exposed. This gives the packaging material a softer, more cushioned texture. Though it is not water resistant like closed cell, open cell foam does does provide more cushion for fragile products that need the same secure contours and presentation.
PET; Polyethylene is the most popular type of plastic used to make custom poly boxes. In fact, it’s the most popular type of plastic period. Compared to polypropylene, polyethylene is more affordable.
PP; Polypropylene is another type of plastic used to make custom poly boxes. It is more expensive than polyethylene and is primarily used when a high level of clarity is needed for poly packaging.
A custom box created with chipboard. The material is similar to particle board which creates a stiff (or rigid) frame for the package design. Once constructed, these boxes most often sport turned edges and are considered “presentation packaging” for their elegant appearance and keepsake status.
SBS stands for Solid Bleached Sulphate. It is a type of paperboard material commonly used to make box packaging. It is the highest quality and most expensive paper board substrate produced from bleached virgin wood pulp.
Silk screening (Screen Printing) is a technique where the printer uses woven mesh to support an ink-blocking stencil. The stencil has open areas of mesh that transfer ink through the covering. A roller moves across the stencil forcing the ink through the threads of the woven mesh that are not blocked. This method is also known as screen printing, silkscreen, and serigraphy.
Like the other dies of the packaging industry, except this die is heated to tightly seal edges. Whether it be plastic pockets in a binder or just a tighter edge on a binder.
A setup box is a custom box also referred to as a two-piece box. Setup boxes are great for retail products. An example of a setup box would be an iphone or ipod box that Apple uses for its packaging.
As the name implies, a slip case slips over a box, creating an extra layer of packaging for a unique unboxing as well as additional information or graphics. Custom slip cases also make excellent packaging for software, books, magazines, or other paper materials.
Soft Touch Lamination
The top shelf of lamination. Like other lams, it adds an extra coating of protection to the custom box its applied to, but it also adds a luxurious soft feel, much like the cover of a textbook. Gives a powerful, yet functional, boost to retail packaging since products change hands so rapidly at the marketplace.
Custom thermoformed trays are a great customization option for box packaging. They are form-fitted to hold whatever contents are needed to be inside of custom box packaging.
Tuck tabs are a popular closing mechanisms used in corrugated/fluted boxes as well as custom poly boxes. For poly boxes, the tuck tabs are die-cut into the poly material.
Turned edge is the manufacturing process of taking a printed cover sheet and wrapping it around chipboard to give a packaging product an upscale look. Common packaging products that use turned edge technology are boxes, binders, and media packaging.
VOC stands for Volatile Organic Compounds. VOC coatings have a high vapor pressure and can be dangerous to human health and the environment. Sunrise Packaging uses UV and aqueous coatings which are VOC-free.