Dieline Design Tips &amp; Checklist

Use Our Free Dieline Generator

$0.00

Cart

No products in the cart.

Dieline Design Tips & Checklist

Crafting your packaging design around a dieline template allows you to be as creative as you'd like with your packaging while still falling within the specific sizing dimensions of the final packaging product. A dieline clearly outlines all the folding marks, cuts, perforations, and glue lines/fold line of the final packaging design, so there's no surprises when you receive the final product. Think of it like a coloring book: you can incorporate as many colors or designs into the picture as long as you stay within the bold outlines of the book.

At CarePac, we provide design templates and dielines for our customers, but it's not uncommon for them to create our use their own. Regardless of whether you use our dieline or a custom dieline you've created yourself, here are some dieline design tips to help you get started.

Tips for document setup

As discussed on our print ready artwork page, all packaging files should be in CMYK color mode. Our preferred format is Adobe Illustrator (AI) or PDF/X-1a, but other packaging companies may have different preferences. You'll always want to check. You'll also need to make sure the orientation of your dieline is facing the correct way - otherwise the text and images of the final design will be facing the wrong way.

Consider the material

Before using a dieline template, you'll need to nail down the packaging material. Some materials (like cardboard) are very thick and rigid, which has an impact on how it folds and where it can be cut or perforated. While cardboard is quite rigid, plastic will conform to the contents inside. On the other hand, if you overfill the plastic pouch it could be hard to seal. Work with your packaging provider to decide on a material and discuss how the selected materials will impact your dieline design.

Factor in size and weight

Depending on what you're packaging, your packaging should not only fit around your product but protect it from damage during transit and storage. For example, nobody wants to open up a bag of chips only to find that they're all shattered into a million pieces. Consider the size, shape, and fragility of your product when using a dieline template to design your finished product.

Leave space for branding and text

This is the important part: without incorporating company branding or additional text on your dieline, your customer won't know what sets your product apart from all the others on the shelf. Make sure there is enough space on the package to include artwork, information about your business and its values, or allergen information for food products. This is the whole point of a dieline: to show you where you can add text and how it'll look on the final product.

Test and prototype

Before you finalize your dieline design and order 10,000 bags or boxes, you'll want to order prototypes of the bag. This helps you see the bag's functionality, exact size, the logos and graphics, and any labels in person before committing to a large order. This way, if you notice any mistakes with the packaging design you can rectify it before you waste too much money on the packaging. CarePac offers custom prototyping from 100 bags, which is a major differentiating factor from some of our competitors with minimums that exceed 1,000-10,000 bags.

CarePac's dieline design checklist

When designing a dieline, you'll want to follow this dieline checklist to make sure you've covered the basics. As always, our helpful team of designers is here to provide their expertise and help guide you through the process.

[ ] Software and file setup

Start your dieline with a brand new vector file in Adobe Illustrator. Your document should be set to the appropriate size and resolution (typically 300 DPI.) Each packaging provider will have different requirements for dieline design, so make sure to check with them directly before submitting a dieline. One thing all companies have in common, though, is using CMYK document color mode.

[ ] Material consideration

Choose your packaging material wisely. Different materials will impact your dieline design in different ways, so work with your design team and make allowances for the thickness of the desired material in your fold and cut lines. You'll want to make sure that the material you choose (and the design) accounts for the product's protection during storage and transport.

[ ] Product dimensions and weight

Make sure you take the time to measure your product accurately. The packaging design template should accommodate the weight, size, and shape of your product. Not only should you have enough room for your product, but you shouldn't make the top of your bag too crowded. If your package is overstuffed it simply won't function as well as a bag with a little room to spare.

[ ] Branding and information

Yes, your packaging templates should leave room for fold and cut lines, but it should also leave room for branding elements, like labels, custom graphics, your own artwork, images, or a little window that lets customer see the product inside. Consider the best placement for visibility and functionality.

[ ] Prototyping

Creating a physical prototype of your packaging design that you can hold in your hands is essential. It's the only way you can sure that you have the correct layout and that your packaging designer has included everything you need into the design.

[ ] Finalize artwork and design

Once you have a physical prototype in your hands and have confirmed that it follows the proper layout, you'll want to finalize the artwork and design. Add a label, account number, or any other custom feature you need. Check your specifications and submit the packaging templates into production. Your job is done!

Free Dieline Generator

Dielines define the physical size of your pouches. Fill out this form and you'll receive the free dieline by email.

Dieline design FAQs

Here are a few comment questions we receive about dieline design:

How do I know my product will fit in the bag?

The best way to make sure your product fits in the bag is to pay for our awesome prototyping service. With as few as 100 bags, it's a cost efficient way to make sure your product will fit comfortably.

Will retailers accept my size and configuration?

In order to ensure your packaging will be accepted by the retailer, you'll need to check with them directly. You may need a hang hole, and they're the only ones who can confirm if the bag size is correct for distribution.

Does it need to stand up?

Although flat packaging is often the standard, you'll need to decide internally if your dieline should incorporate the need to stand up into it.

Do I have to create my own dieline?

No! CarePac provides design templates, which can be customized to your liking. Because all our packaging is made to order, you have control over the dieline structure and layout.

CarePac: Your partner in dielines and packaging

As you can see, creating packaging isn't always easy. Whether you're packaging food, clothing, coffee, or snacks, our designers can help you incorporate all the necessary elements onto your bag. From images to folded lines, dielines act as a blueprint to your final design and should be taken seriously. Whether you use your own graphic design software or leverage our design team, dielines are the best way to refine packaging so the final product is exactly what you're looking for.

Download our dielines today!

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Flexible Barrier Packaging

Barrier Packaging Guide

$0.00

Cart

No products in the cart.

Barrier Packaging Guide

Choosing the right packaging materials for your product can be a daunting task. Not only does the packaging need to look great, but it needs to protect the perishable products within, working to extend shelf life and extend freshness. Additionally, you'll need to take a variety of things into account: how long will the product be in storage? Will it be stored in a climate controlled environment, or outside in a hot and stuffy warehouse? Does the packaging require more than one layer of protection, or just one?

Fortunately, you're not alone in your hunt for the perfect barrier packaging material. Our barrier packaging guide will walk you through some of the most common questions we receive about barrier packaging, the advantages of an oxygen barrier, and more. Welcome to our guide to barrier packaging, created by the people who know barrier packaging best.

What is barrier packaging?

First things first: what is barrier packaging? Barrier packaging is any packaging that prevents the migration of moisture, gas, or oxygen through the packaging, creating what some refer to as a modified atmosphere package. This barrier can be thought of as a firewall, preventing the movement of gas or liquid. In short, barrier packaging is made from a packaging material that provides a high barrier between the product inside and oxygen, moisture, light, and gas. In some cases, barrier packaging can also act as an aroma barrier, keeping products fresh and odors and scents inside the plastic bags.

How is barrier measured in packaging?

The two main measurements of barrier are moisture vapor transmission rate (MVTR) and oxygen transmission rate (OTR). There are other measurements, but for food products these are the most common measurements. Learn more about what exactly these measure in regards to barrier packaging materials.

Moisture vapor transmission rate

This is measured using standardized testing protocols from ASTM or ISO. Grams per square meter over 24 hours (g/m²/day) is a common measurement, and it measures how many grams of moisture are transmitted through the packaging material in a 24 hour period. In the United States, some companies use grams per 100 square square inches over 24 hours (g/100 in²/24 hr) which measures the amount of moisture passing through 100 square inches of material in 24 hours.

Oxygen transmission rate

Typically measured in CC/100in square in 24 hours (cc/m²/day), this measures the amount of oxygen that passes through the material over a specific area across 24 hours. In the United States, some companies use CC/100 in²/day, which measures square inches per 24 hours.

Understanding these common measurements for barrier packaging materials can be confusing, which is why it's so important to work with a professional and experienced packaging company, like CarePac. We'll walk you through the various oxygen and moisture barrier properties, ensuring that the packaging material you choose has the barrier properties you need.

What are the different levels of barrier protection in packaging?

When it comes to understanding the different barrier levels of plastic films, they're typically divided into four categories: basic single, basic double, moderate, and high performing. Each level offers a stronger oxygen and moisture barrier and the barrier strength increases with each step up. Here's a little more information about the barriers and the metallized films that fall within each category.

Basic Barrier- Single Layer

This offers your most basic level of moisture and oxygen barrier. It temporarily protects the product within from exposure to light, oxygen, and moisture, but won't do much to extend the shelf life of the product. Think of this as your most basic low barrier material, such as the monolayer materials that make up a sandwich bag. If you're on the hunt for a high barrier material, keep looking!

Basic barrier- Multilayer Materials

Basic barriers that use multilayer materials are still relatively "basic" in nature, but they do offer enhanced protection when compared to a basic barrier with a single layer. Often associated with laminated packaging, you'll often see a combination of materials in a double layer barrier. For example, PET/PE combines polyethylene terephthalate and polyethylene, OPP/PE combines oriented polypropylene and polyethylene and OPP/OPP has two layers of oriented polypropylene.

Polyethylene Terephthalate (PET) provides a good barrier against gas, moisture, and aromas, and is often used in multilayer basic barriers.

Moderate Barrier

A moderate barrier will often protect against gas, moisture, aroma, and sometimes UV light. These coated films are lightweight and food safe, and are often used for food packaging. CarePac's PET/VMPET/PE is considered a moderate barrier material, and the metallization of these films offers an enhanced oxygen barrier. Unlike the basic barriers, a moderate barrier can help extend the shelf life of food, pet treats, and other items.

High performing barrier

Finally, high performing barriers are made up of multiple layers of heavy duty materials. Our high performing barriers protect against odor, moisture, gas, UV light, and visible light, and will keep the product inside fresh. If you're concerned about your product being exposed to gases, chemicals, and other detrimental elements in the environment, choosing a high performing barrier is essential. CarePac's PET/AL/PE bags use aluminum foil as the middle layer, which has incredible barrier properties, and is nylon reinforced for super protection and durability.

Which barrier should you choose?

So, which level of barrier protection is right for you? While a higher barrier is always better, especially for food products, excessive barrier is just a waste of money. Selecting which level of barrier you need also depends on a variety of unique factors, such as whether or not you need a window to view the product inside. For example, if you don't need a window, choose a metalized material with a better barrier.

We know this can be incredibly confusing, which is why it's so important to work with an experienced and qualified packaging company that's well versed in flexible packaging and barrier properties. Curious about the advantages of one barrier level over the other? Need help with the development of your packaging? We can help! Contact us today!

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

A Guide on How to Get Your Product in Stores

$0.00

Cart

No products in the cart.

A Guide on How to Get
Your Product in Stores

Whether you're a brand new business trying to get your product in stores or are an existing business that's toying with the idea of expanding your existing product line, getting your product into retail stores like Target, Wal-Mart, or another big box retailer is often times a "make it or break it" situation. If this kind of business sounds like you, here are a few tips on how to get your product in stores, from smaller stores and local retailers with only a handful of storefronts to major retailers with stores nationwide. Wondering how to get your product in stores? Read on for our helpful business tips!

Identify the right store

Before you approach retail stores, do market research and understand where your potential customers and target market shop. Most entrepreneurs automatically assume that getting their product onto the shelves of large chains is the best way for them to sell products, but for many businesses it's just as important to establish relationships with small business owners in your own town.

If you haven't already researched your customer base, business clients, and target market, do so immediately. This will help you understand more about your potential buyers, the price points they look for in stores, and whether they shop online or in person.

Start small and gradually expand to more retail stores

If you're a small business owner yourself, the best advice we can give is to start small: consider a hybrid approach where you sell products or t shirts on online marketplaces, virtual trade shows, AND local stores. Establish a customer base, work on building relationships with your online customers and vendors, and then consider expanding to a national chain with a multitude of stores. Once you've identified the right retail store, it's time to move onto the next step.

Pitch your product to the retail store

So, you've identified the right retailers and local stores. Now it's time to pitch your product to the online or big-box retailers. In some cases you'll be pitching your product to the store owner in person and in other instances you'll be meeting with retail store owners virtually. In both scenarios, you'll be meeting with key decision makers, so this is your opportunity to create hype around your brand and business.

Partner with a marketing business

If you've never pitched a product to retailers or local stores before, you may want to partner with a marketing business that's well versed in putting together marketing emails, can calculate projected sales numbers in your target market, can project demand among your buyers, and understands what a decision maker looks for during the product pitch for their store. This is one area where you do not want to be unprepared. Sales matter, so consider hiring a sales person who understands your market.

Understand the requirements for products & product packaging

What are the requirements larger retailers have for their new products? What are absolute must-haves for packaging? Here are a few things your small business should keep in mind, especially if you'll be meeting with larger retailers in an effort to get your product in stores.

Compliant packaging

Is your packaging compliant with local regulations? Buyers care! Things like PFAS and meeting FDA standards are all very important to small, medium, and big retailers. CarePac can help ensure that all your packaging is compliant, which is something overseas suppliers can't really provide.

Packaging size for local stores

Unlike other companies that make you fit THEIR packaging, CarePac can fully customize your the size of your packaging. This way, you're maximizing the space you do have on the store shelves. If you approach retail stores with packaging that's way too big for your product, this makes you look disorganized and unprepared.

Barcodes and QR codes

This is especially important if you're focusing on online sales, as many online retailers require bar codes with identifying information, such as pricing information. Whether it's an Amazon ASIN, a scannable QR code, or a standard barcode, make sure your product packaging has whatever information potential investors would be looking for.

Come to the meeting prepared

This is one area of finding the right store where you don't want to fake it 'til you make it. Fortunately, CarePac can help you impress larger retailers and potential buyers with our prototyping. We're able to print as few as 100 bags, so you can go to the meeting with actual product samples in real product packaging. This can help get your product into stores because the big-box or local retailer will be able to hold your product in their hands, packaging and all.

Skip the mock-up; bring the real thing

Many small businesses go to these meetings with a mock-up or an "idea" of what their packaging will look like. Why not take it a step further and show the brand you're meeting with that you put a lot of thought into pleasing potential buyers with amazing packaging.

Find a good co-packer

Finding a reputable co-packer means that they'll have the necessary equipment, production capabilities, and retailer staff to help you increase production when you need to. This way, if you see a huge boost in sales, either online sales or at retail stores, you won't have to worry about whether or not your co-packer can handle the increase in volume. Ask your co-packer about their ability to scale up, especially if you plan on adding new products or increase sales through an intense marketing campaign.

Consider cashflow

Now comes the boring part: line sheets, ledgers, managing stock and inventory, and making sure your product can be replenished repeatedly without going into the red. Many retailers and stores pay you long after your customers and buyers purchase your product, and others are notorious for running on consignment- meaning you won't get paid until (or if!) you sell your product. Additionally, you might pay more for getting your product into stores that offer premium placement or endcaps.

This is the dark part of how to get your product onto store shelves that nobody talks about. Make sure you have a healthy savings account and are prepared for the product in stores to sit on the shelves a bit before you make any kind of profit.

Make sure your product stands out on store shelves

Now that you know how to get your product in stores, it's time to think about how to stand out from all the competitors who are selling similar things.

Ready to sell your product in stores, online, or at local shops? If the demand is there, we can help you take your business to the next level with the very best packaging. We can help you create packaging that's the real deal- it will help you stand out in your local area, nationwide, and everywhere in between. Regardless of what you're selling (or where -- online, in stores, it's all the same to us!), we can help package it.

Working with us is incredibly easy. We're a business, too, and we have experienced a lot of the same pain points as you. Your best bet for high-quality packaging that can help you lower costs and stand out at stores, is to work with us to create the perfect packaging.

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Packaging Design

Color Gamuts

$0.00

Cart

No products in the cart.

Color Gamut: Maximizing Vibrancy
in Flexible Packaging Design

Introduction to Color Gamuts

Ever picked up a product, drawn in by its flashy packaging, only to find the actual item a shade or two duller than expected? Frustrating, right? That is the persuasive power of colors (specifically red, green, and blue) in flexible packaging. This visible color spectrum (in addition to accurate printing of the colors and how it can affect image quality) may make or break our views and influence our decisions to buy.

Welcome to the vibrant world of packaging design, where each tone, hue, color temperature, and shade serves as a calculated visual trick to grab your attention in addition to being a visual pleasure. The vivid pop of colors in your favorite candy wrapper, or the lively crimson of a just plucked apple. These eye-catching moments? They're not random—they're carefully crafted using the wonders of color standards and the color gamut.

Now, hold your horses! What is color gamut, you ask? Think of it as a magician's palette, but instead of tricks, it conjures up the exact cmyk or rgb color space, shades, and tones a designer needs to make your packaging pop. The color gamut refers to the secret sauce for delivering graphic design with accurate, vibrant colors that leap off the shelf and into your shopping cart. Without these color standards, the colors you see commonly represented on a product's packaging would be dull and washed out.

Understanding this wider color gamut isn't just insider knowledge for designers. It serves as your pass to enter a world where packing is an experience rather than merely an outer layer. Come along on a vibrant journey as we explore the mysteries of color gamuts and learn how perfecting the color space enhances the appearance, texture, and appeal of the printed image on flexible packaging.

Understanding Color Gamut in Flexible Packaging Design

The color gamut is limited, yet it is like a treasure trove of a range of colors, hues, and tones. It's the range of colors at our disposal, similar to selecting the same colors from a box of crayons. But here’s the catch—not all surfaces or materials play nice with every crayon in the box. This is where the larger color gamut comes into play.

When it comes to flexible packaging, think of it as a canvas that comes with its quirks. It's what allows your designer to produce colors and depict colors on paper as they are in your mind. The type of material used, the printing methods, and even the inks—they all have their say in how vibrant the wider range of colors on your favorite snack bag turn out. Essentially, the wider color gamut won't always play nicely with every type of material.

Ever wondered why that fiery red on a plastic pouch doesn’t quite match the same red on paper when viewed with the human eye or on LCD monitors? The visual differences between these color spaces on a computer monitor, an analog television, or on digital cinema is the broader color gamut at play!

These factors, from the material of the package to how the colors are applied during photo or video editing, dance a complicated tango affecting the reproduction of a wider range of actual colors. Some colors might look bolder on certain materials while the image quality may appear a tad lackluster on most displays. It's like trying to reproduce different color standards on different surfaces—each one gives a slightly different outcome.

But fear not! The color gamut dance gives designers the upper hand with color spaces. They tweak and tune their color selections to match the strengths and limitations of these packaging materials, ensuring what you see is what you get. It's like having a magical recipe that cooks up the exact colors they intend, making that bag of chips or that shampoo bottle pop off the shelf with just the right shades.

Importance of Accurate Color Reproduction in Flexible Packaging

Ever picked out a product from a lineup because you recognized its packaging primary colors from a mile away? That's the magic of using a consistent range of colors —your brain's way of saying, "Hey, that's my favorite brand!" But what happens when this range of colors play a game of hide-and-seek due to the limitations of such a wide gamut?

Imagine this: your go-to cereal box suddenly appears a shade lighter than usual. Or worse, the vibrant blue or CMYK inks on your favorite snack bag seems more like a faded memory. It's not just a visible spectrum color change—it's a hit to brand identity! Consistent colors hitting the human eye are the superhero capes of branding, instantly signaling familiarity and trust.

When color gamuts throws a curveball, it's not just about a change in hue; it's a hit to the brand's harmonious symphony. The RGB color space and hues that consumers have grown to identify with dependability and image quality may not be as accurate as they recall, leading them to second-guess their selections. It's similar like meeting a buddy disguised; you may ultimately identify them, but it will take some time and isn't exactly the same.

Consider the success stories: iconic brands that have nailed the color coverage game. Think about the saturated colors of Coca-Cola red or the Tiffany blue. These brands have mastered the art of consistent color reproduction, becoming instantly recognizable just by their hues. On the flip side, imagine a product whose packaging fails to keep up with its color promise—confusing, right? That's the gamble when the color gamut limitations muddy the waters of recognition. If you want more accurate printing, pay special attention to your display's color gamut, particularly in ultra high definition resolutions.

So, hold tight to that familiar feeling, because in the world of flexible packaging, accurate color reproduction isn't just about making things look pretty. It's the glue that holds brand recognition together, ensuring you reach for that familiar package on the shelf without a second thought.

Importance of Accurate Color Reproduction in Flexible Packaging

Printing technologies take center stage here.

Rotogravure, the go-to rockstar of printing on flexible packaging, making the wide gamut of colors sing on materials like plastic and films. Then there's digital printing, the newer kid on the block, showing off its prowess in reproducing intricate designs with vibrant colors. These technologies aren't just different ways to print—they're the conductors orchestrating the wider color gamut you see. They're what take photography technology and color gamut standards to the next level!

But wait, there’s more to this colorful ensemble! The substrate materials

The very canvas for these colors to dance upon—play a crucial role. Some materials, like paper or certain plastics, embrace colors with open arms, while others might be a bit more reluctant, causing those colors to shy away a bit.

Enter the color management heroes!

These systems and tools are like wizards wielding their magical wands to ensure that the wider color gamut you see is what the designer intended. They tweak and fine-tune the color model to fit the capabilities of the printing devices (and technology like LCD monitors, OLED technology, and the internal camera on a laptop) the materials, ensuring a harmonious visual feast for your eyes.

Yet, despite all these enchantments, challenges abound. Imagine attempting to create a masterpiece with a little supply of brushes and a canvas that doesn't exactly take paint well. That's the struggle designers face with the color gamut—juggling the desire for specific colors within the boundaries set by printing devices, LCD monitors, digital video capture, or an iPhone x's internal camera.

Strategies to Maximize Color
Gamuts for Effective Packaging Design

First up: color profiling.

Color profiling in the context of a color gamut is like tailoring a suit to fit just right. It's similar to customizing a garment to fit perfectly. To ensure that colors are as brilliant as possible when they reach the package, especially if you're designing using most computer monitors, designers precisely adjust colors for the printing process and the materials utilized. Then comes color separation—it's like breaking down colors into their individual components to ensure each one stands out, playing its part in creating a vivid visual symphony.

But hold your horses! We're not done yet. Ever heard of color space?

Think of them as different playgrounds for colors. Designers have access to a broader range of tints and tones when they select the appropriate location, which allows them to broaden their palette. It's similar to having more crayons in a larger box, allowing designers to better reproduce color, from light magenta to the white point on a package.

Now, here's the big secret: collaboration is key!

Designers, printers, and manufacturers need to join forces like superheroes in a league. When they work hand in hand, sharing insights and expertise, that's when the magic happens. It's not just about one person wielding the color wand or adhering to the SRGB standard—it's a team effort to ensure those red, green, and blue colors dazzle from the shelf to your hands.

Imagine a world where every color on your favorite snack bag or beverage bottle looks as vivid and enticing as it does in your imagination. That's the promise of these color model strategies—taking the limitations of the color gamut and stretching them like a canvas, letting designers create vibrant, eye-catching packaging that's nothing short of a work of art.

Conclusion

In the world of flexible packaging and image quality, the standard color gamut isn't just a toolbox—it's the magician's wand that transforms ordinary packaging into captivating experiences. Its limitations and possibilities dictate the vibrancy and accuracy of colors that catch our eye. From the dance of printing technologies to the harmony of color management, it's a symphony of technical prowess and artistic finesse. Remember, in the realm of packaging design, understanding and mastering the wider gamut of accurate colors is the gateway to making colors speak volumes!

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Prototyping In Packaging Design

$0.00

Cart

No products in the cart.

The Role of Prototyping in Perfecting
Your Packaging Design

Nothing influences a customer's first impressions and perception of product quality more than product packaging. Customers expect their product packaging to be environmentally conscious and to provide a memorable unboxing experience. Bonus points if your product packaging can help you reduce costs, improve profit margins, and reduce your carbon footprint.

What is prototyping?

A prototype is an early sample, model, or release of a product that's built during the design process to test its construction or design. In terms of packaging, a prototype is a limited run of bags or pouches that act as a sample of what the final product will look like. Some packaging prototypes just look at size, while others can be printed with the design of your choice so you can take a final look at the pouch before you put in a larger order.

Realistic prototypes allow you to avoid costly mistakes and evaluate, test, and refine an idea before it enters mass production. The primary goal of rapid prototyping is to test the pouch for functionality, usability issues, to get user feedback, and to see all the detail of the final bag in real life. In this blog, you'll learn more about the different prototyping offered by CarePac.

CarePac's High Fidelity Prototyping Process

CarePac focuses on offering customer the most customized experience including our prototyping services. low fidelity prototypes have limited usefulness (see more below) A prototype is only useful if it accurate emulates the final product. Hence CarePac offers two main types of prototypes.

Unprinted Sizing Prototypes:

These are machine-made prototypes that are unprinted. They are effective for validating sizing, configuration, and material.

Machine made prototype

Great for sizing and material testing

Lowest cost high fidelity prototype

unprinted sizing prototype carepac Prototyping In Packaging Design

Digital Printed Prototypes:

Fully customized and printed high fidelity prototypes of 100 bags. These are real bags, and fully functional prototypes made with the same processes and procedures as your final product.

Machine made prototype

Digital print check, sizing, and material testing

From $250 for 100 bags

Sink Print Prototyping:

For both digital and rotogravure printed projects, we can provide a print skin. these can be thought of as high fidelity prototypes of the bags printing. These are not useful for sizing, but only for confirming color outcomes on film.

Rotogravure printed or Digital printed prototype

Print or color check only, not for sizing or material
Creates delay, but no cost unless make change

Understanding Prototyping in Flexible Barrier Packaging

At CarePac, we pride ourselves on our low MOQs, meaning you can order as few as 100 functional prototype bags. Some other companies don't offer prototyping for user testing, meaning your final design is based on clickable wireframes, rough designs in mobile apps, or the most basic form of early prototyping: low fidelity sketches. Still others only offer low fidelity prototypes such as paper prototypes, and handmade prototyping these low fidelity prototypes have some uses, but here at CarePac we focus on offering high fidelity prototypes including short digital porotypes and skin print prototyping, From unprinted samples to plate printed prototypes, here's a little more information about the types of prototyping and the methods of prototyping we offer here at CarePac.

Paper Prototyping

At least in the packaging world a paper prototype is part of the design process that used by some customer to visualize the final product. A Paper Prototype is a very low fidelity prototype that is best designers to refine design thinking and processing how the design will look on a 3d surface. Paper prototypes are functionally useless beyond refining your thinking about a pouch design.

Handmade Prototyping

Handmade sizing samples are low fidelity unprinted prototypes offered by some of our competitors which are exactly what they sound, they are a unprinted hand made bags. These handmade prototypes are a step above paper prototypes because unlike paper prototypes, handmade prototypes are made of flexible barrier material and generally to the same size as the final product.

But CarePac steers clear of handmade prototypes for several reasons. The seal quality of a handmade prototype will not be the same as a machine made product, So handmade prototypes cannot be used for technical testing (blow out, seal strength, MVTR, or OTR tests, etc). Second, if sizing is what you are wanting to confirm, why not just invest in high fidelity porotypes such as our digitally printed bags? With high fidelity prototyping you can also confirm print placement or color along with other physical parameters and material performance. Second, If the prototyping is for color check, only a high fidelity prototype such as a digital prototype or a skin print will get you close enough to the final product to satisfy what you want.

Unprinted Sizing Samples (low fidelity prototypes)

This is exactly what it sounds like: an unprinted bag that's perfect for people who are only worried about the size of the bag (not its design concepts or uncovering usability issues during usability testing.) These bags are unfinished and unprinted, and are built to the specific sizing you provide and with the material you want to use on on the final product.

We consider these machine made sizing prototypes to be a mid-ground between low fidelity prototypes such as paper prototypes or hand made prototype bags, and the high fidelity options of a digitally printed prototype or a skin print prototype. The real advantage of the unprinted sizing sample is you can try to fit your product into the prototype so you know it'll fit into the final version of the bag or pouch. You can also test other physical attributes of the bag. Finally it can also help with your design thinking process, as it's a 3D object you can sometimes better visualize where you want the art placed as opposed to using paper prototyping, or other low fidelity methods.

Unprinted Sizing Samples low fidelity prototypes Prototyping In Packaging Design

Digitally printed prototyping

CarePac's digitally printed high fidelity prototypes are micro short production runs of as few as 100 bags (or 1 bag if you really just want 1 bag), and these digital prototypes can be printed onto any custom size bag you'd like, with almost any material we work with here at CarePac. Many of our customers prefer a digital prototype for a variety of reasons beyond prototyping such as trade shows, promotional events, influencer targeting and more. The most common use of high fidelity digital prototyping, including the below.

Solidify sizing

The digital prototyping process helps you ensure that the size of the bag is correct for your product. If the lo fi prototypes are too large or small for your product, you can adjust. Again Unlike paper prototyping which leaves room for error and differences in how the material reacts, our digital prototypes are made on the same machine and using the same processes as your final product would be.

solidify size Prototyping In Packaging Design

Performance testing

CarePac's Hi fi prototypes can be fully customized and made with any material we can source which allow you to conduct performance tests, so you can make sure the material meets the needs of your application (ex: you can perform test shipments to make sure the bag doesn't burst during transit.) A common use case for our high fidelity digital prototypes would be protein powder. A low fidelity prototype like a handmade sample or paper prototype cannot be used to test whether the bag will hold up to rough handling in a amazon warehouse.

Meeting preparedness

Gives you the opportunity to show actual samples to prospective retailers and distributors. Instead of showing up to a meeting with just an idea for a preliminary model, you can actually show up to the meeting with a finished product that shows off your bags interactive elements. This really is a great example of the difference between a low fidelity prototype, such as a paper prototype and high fidelity prototypes that we can make here at CarePac.

The old saying "Fake it until you make it" comes into play here, but in all honestly retailers, distributors and partners can better visualize your product and it's place in their store when you provide a fully finished and printed bag prototype. Spending a few hundred dollars for high fidelity prototyping from CarePac could land you a six figure distribution deal, and we think you'll agree it's worth it on so many levels.

Meeting Preparedness Prototyping In Packaging Design

Skin print prototyping method (another high fidelity prototypes)

Think of this as a high fidelity prototype: it allows you to confirm the colors of your project on actual printed material. Using hi fi prototypes is great if you plan a long run and want to confirm how the colors perform on the actual material of the bag. For example, if your UX designer or UX design team prefers using a specific CMYK color on a specific material but the prototype and focused feedback shows that the color bleeds into the material, you may want to consider a different material or color.

This is also important because sometimes colors look different on different screens than they do in real life. You'll want to see what real users will see - not what your design team sees on a screen.

plate printed prototype Prototyping In Packaging Design

Plate printed prototypes

This is the most complex kind of prototyping, as it requires us to use plate printing (to learn more about the complexities of plate printing, you can read more here.) With this prototyping process, your design team will lose nothing but time (approx. 2 weeks) if you approve the skin print as is. But, if you want changes after the skin print, you'll incur the costs associated with making the change in addition to the costs of the time and the material to print along with any plate remakes.

For this reason, we recommend skin print digital prototypes unless you are only checking for PMS color accuracy.

Benefits of building prototypes during packaging design

There are quite a few benefits to using a physical model of your bag or pouch to test ideas among real users.

Risk mitigation

Relatively speaking, incorporating interactive prototypes into your design thinking process requires minimal effort. And it's, quite simply, the best way to catch mistakes before your bag enters mass production - potentially saving you time, money, and embarrassment.

Enhanced communication

Using a high fidelity prototype during the design process allows design teams, clients, and manufacturers to discuss the user's journey and how the final product will satisfy user needs.

User testing opportunities

Last but not least, the only way for a UX design team to understand if their product satisfies user needs is by leveraging popular prototyping tools and services (like CarePac) during the development process.

Other types of prototyping techniques

There are a few different types of prototyping techniques, from clickable wireframes and audio simulations to to mid fidelity prototypes. Here are some of the user driven prototypes used by the packaging industry.

3D printing

This is one of those digital tools that's a good choice for complex designs since it allows for the rapid production of detailed models. One thing to keep in mind, though, is that the 3D printed version of your pouch may not be of the same material as your final product, as the types of materials that can be used with 3D printers is still limited.

Mock-ups

Primarily used for visual presentations, this is a type of low fidelity prototyping that is less functional but visually accurate. You won't be able to hold the finished product in your hand, but it can be a good way to test ideas related to marketing or branding during internal meetings. Mock-ups are often leveraged earlier on in the design thinking process.

Digital simulations

Useful for initial design evaluations, digital prototypes can help teams validate ideas without a physical model. These high fidelity prototype tools involve creating a visual representation of the packaging, that often includes logo placement and the intended user interface.

Physical prototypes

Physical prototypes are, simply put, the best type of prototyping. It allows teams to validate ideas, handle the finished product in real life, pursue user testing, and see each step of the design thinking process come to life. These prototyping tools create existing objects that can be passed around a room, and is a much better option than some of the low fidelity prototyping on this list. CarePac digital prototypes are physical prototypes.

We can help you choose a prototype technique
Each of the above method has its own place, depending on the complexity, materials, and specific project requirements of the final product. Fortunately, CarePac can help you select and create prototypes that are most appropriate for your project.

How to integrate prototyping into your workflow

If you'd like to create prototypes for your company, you may be wondering how to incorporate these user driven prototypes into your workflow.

Engage the team early

In order to best incorporate prototyping into your design process and thinking, introduce it as early on in the process as possible. This allows enough time for refinement.

Take a collaborative approach

Encourage all members of the team to be involved in the creation of physical models through prototyping. This includes designers, engineers, and manufacturers. Each of these groups will likely have something unique to contribute re: user interfaces and how the prototype will help the overall design process.

It's an iterative process

View prototyping as an iterative process, where each prototype brings you closer to the ideal final product. Very few companies move forward with their very first prototype; instead, they tend to go through a few physical models before they decide on the right one for them. Whether you choose low fidelity or high fidelity for your prototyping, any such prototypes will greatly improve the success of your final product.

CarePac: Your partner in packaging prototypes

Prototyping involves several areas from design, to function, and can be more complex than you'd think, but CarePac can help. If you're interested in leverage high fidelity prototypes for your company, connect with us to get your project started. You can also order samples here.

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

how-to-calculate-roll-diameter-online-measuring

Packaging Calculators

Roll Diameter Calculator

Determine Diameter of Roll Material

Roll Diameter Calculator to Determine Diameter of Roll Material

Whether you’re a brand new client or a repeat customer, determining the appropriate roll diameter is essential to keeping your business running smoothly. If the roll diameter is too large or too small, it won’t fit onto the machine it’s going on to. Both scenarios aren’t ideal, which is why nailing down the appropriate roll diameter you need is so important.

Determining the appropriate roll diameter can be quite confusing for many of our customers, but our roll diameter calculator does the calculation for you.

how-to-use-roll-diameter-calculator-carepac

Using Our Roll Diameter Calculator

Our interactive calculator is incredibly easy to use: simply input the requested dimensions (core diameter, the thickness of material, and length of material ), and our calculator will crunch the numbers and let you know the outside diameter of the rolled material. This way, you can quickly order the accurate roll diameter for your machine and application.

For example, if your machine offers a max roll diameter of two feet and you want to figure out how to fit 10,000 feet on the roll, our calculator can help. One important thing to remember is that our calculator does not account for variations due to stretching or softness of the material.

Additionally, while our free tool will assist you in determining the outside diameter of the roll material, this calculation should be used for estimates and is not an exact measurement.

Get Started with CarePac

Whether you’re ordering standard-sized rolls or are looking for something more customizable, CarePac can help support all your packaging needs. With decades of experience in the packaging industry, no job is too large or too small for our team of professionals. Have questions? Want to get started? Get a Quick Quote, order samples, or contact us today for more information.

Roastar Alternatives

Roastar Alternatives:

The Top 4 Competitors for

Custom Coffee Packaging

Roaster is known for its fast turnaround in the flexible barrier packaging industry. Flexible barrier packaging materials keep coffee fresh through shipping and extend coffee's shelf life.

Flexible barrier packaging is essential in the coffee industry. You won't get far with stale coffee. This packaging method uses flexible materials that seal in freshness and keep moisture and light out.

This post will explore the alternatives to Roastar in the custom printed label coffee bag industry.

Roastar's Alternatives for Custom Printed Labels

Roastar

Roastar is a custom-printed packaging company that advertises super quick lead times. The company offers some fantastic design options. This company has industry-standard bags and pouches. Roastar even offers tin cans to provide an extra strong oxygen barrier.

Roastar also creates excellent custom-printed bags, but they fall a little short in a few areas. If you are still looking for the perfect company for your custom packaging, here are some great companies to consider.

Savor Brands

Savor Brands is a company based in Hawaii with a reputation for sustainability. They promote R+R upcycling, which disposes of non-compostable high-barrier packaging.

Savor Brands' attractive and customized coffee bags are great for cafes and retail stores. The company has an eight to ten-week lead time, which might not be ideal for your growing business.

TriCor Braun

TriCor Braun is a massive international corporation. It serves businesses in multiple countries with its vast selection of packaging options.

TriCor Bruan also has a plant-based packaging material called Biotrē. This material is compatible and eco-friendly. Biotrē also comes in a variety of styles.

However, TriCor Bruan is a massive company. It lacks a personal touch. Its designs and features are sleek and professional but leave little room for customization.

CarePac

CarePac is a family owned flexible barrier packaging that puts the customer's experience and vision first.

CarePac offers total customization of your pouch's size, configuration and printing. Its high-quality, customizable, flexible barrier packaging is perfect for coffee brands large and small. The company has printing solutions that will scale with your business.

CarePac uses plate and digital printing. Digital is excellent for a smaller-scale business. But plate printing is a lot cheaper at a higher volume. If you plan on growing your business, you want a printer that can save you money in the long run.

CarePac has packaging plans that will scale with your account from 100-100,000 bags and cover everything in between.

Who Produces the Best Custom Printed Bags?

The two big contenders for custom-printed coffee bags are Roastar and CarePac. TriCor Braun and Savor Brands remain decent options. But neither of those brands can offer specialty flexible packaging at the same level as CarePac and Roaster.

Roastar exclusively uses a digital printing process and primarily fixed bag sizing. This process allows the company to have a lightning-quick lead time.

Those fast turnaround times leave something to be desired in customizability. Roastar offers customers set sizes of bags. You can't change or modify the size of your bag to fit your style and design.

Roastar only offers a few sizes of genuine square-bottom bags. These bags are ideal for display. Roastar focuses more attention on side-gusseted bags. These bags are extremely common in the coffee industry. But you don't want your brand to be common.

CarePac is the winner when it comes to personalization and brand development. They use digital and plate printing. Digital printing is fast, but plant printing is more cost-effective as your business expands.

CarePac also allows customers to pick the size of their bags. It is 100% up to the customer. They Give great personalized attention to every order. The owner is directly involved in processing new orders.

CarePac also provides competitive lead times, with their fastest being three weeks. That time is used to complete your packaging order to your exact specifics. The care and expertise of CarePac are worth the slightly longer wait.

What does Carepac add to the experience of their Customers?

CarePac is a family-run business. You are guaranteed to have a personalized experience from quote to delivery. The owner personally checks every new order.

CarePac offers bags made in the USA.

CarePac offers these coffee bag configurations:

All of these configurations can be altered to fit your needs. They do not have standard size for their coffee bags. You are totally in control.

Carepac: A Standout Competitor for Stand-up and Flat Bottom Pouches

Digital Printing for Your Coffee Bags Roastar Alternatives

Roastar can offer speed, but is speed everything? What your company needs is flexible packaging that fits your brand. That is where CarePac outshines the competition.

When it comes to stand-up pouches, gusseted bags, and flat pouches made the way you want them, CarPac is the flexible packaging company for you.

Choosing the Right Custom Coffee Packaging Company for You

No one knows your company better than you.

You want a company with a personal touch to accommodate your brand as it grows.

With Roastar, you are limited to a digital printer and set sizing. These limitations make it harder to realize your dream packaging with Roastar. Though Roastar's results are fast, they are less specific to your brand.

CarePac does what its name suggests. The company cares about your brand and will create flexible packaging that fits your needs and design aesthetic. CarePac doesn't push you into a solution that isn't perfect for you.

Roastar does offer a few different sizes and a range of customization options, but it isn't as flexible as CarePac. Roastar's flat pouches and square bottom bags only come in a few select sizes.

CarePac specializes in flexible packaging. It lets the customer choose the printing process that best suits their needs. It is a family brand that will grow with small businesses and help large companies continue to flourish.

Visit the CarePac website today,

order some samples, and make your flexible packaging dreams a reality.

Non Food Items Packaging

Ecommerce Packaging Guide

$0.00

Cart

No products in the cart.

Ecommerce Packaging Guide

Ecommerce Packaging Guide:
Enhancing Customer Experience

If you perfect your product packaging, your target market and new customers will start to associate your commerce packaging with your brand. For example, Tiffany has become synonymous with its blue packaging materials, and brands like Glossier have made their commerce packaging part of their customer's online shopping experience.

Simply put, your retail packaging can help solidify your brand identity, which is why it's so important to create commerce packaging that's the right fit for your small businesses.

Factors to consider in ecommerce packaging

When it comes to perfecting your ecommerce packaging, there are a few things to consider. Depending on what your e commerce business sells, some of these custom packaging solutions and features will be more important than others.

Functionality and protective packaging

If you're a packaging company that ships fragile items, you'll need to choose packaging materials and designs that will ensure the safe transit of products. This includes adding features like bubble wrap, foam inserts, and padded mailers when you create packaging. Other things to consider include using a padded envelope or adding extra tissue paper and environmentally friendly packing peanuts to your ecommerce packaging.

At the end of the day, better packaging is ecommerce packaging made from recycled materials that's cost effective and protects what's inside from damage during transit. Your packaging supplies should be efficient and durable.

protective ecommerce packaging solution Ecommerce Packaging Guide

Branding and unboxing experience
(+ frustration free packaging)

One of the best ways to boost customer retention and help stimulate repeat purchases is to focus on creating a positive unboxing experience for your customers. You should make sure this unboxing experience aligns with your brand's identity and will foster customer engagement. Use frustration free packaging, ensure your production and shipping process is seamless, and consider using custom printed tissue paper to ship products. Throw in a few extra stickers as an added bonus!

It's small details like this that can make the unboxing experience memorable, creating a positive impression, enhancing perceived value, and improving customer loyalty.

Sustainable and eco-friendly packaging materials & practices

Let's face it: customers are caring more and more about brands using and creating packaging that's eco-friendly and sustainable. Use packaging supplies or a poly mailer that's recyclable or compostable (i.e., Kraft paper), and offer customers the option to offset the carbon impacts of the delivery process. Many customers are willing to spend a little more on shipping costs if it means their custom packaging isn't negatively impacting the environment.

Other things to consider include using recycled paper, leveraging a nearby fulfillment center, and using recycled materials in lieu of bubble wrap or bulky protective packaging.

eco-friendly-ecommerce-packaging-material

Weight of your custom boxes and packaging options

One of the biggest things many ecommerce brands are trying to do is to reduce weight to get their shipping boxes and other packaging options into flat rate shipping tiers. For example, the maximum weight for USPS first class packaging is 13 oz. This dimensional weight limit includes the packaging, and this is one of the hidden costs of the shipping and packaging process.

We can help ensure that the packaging solution our packaging specialists create for you won't weigh more than you intend it to.

Best practices in ecommerce packaging

If you're engaging with a packaging expert to help you design and create your e commerce ready packaging, here are a few things to keep in mind as you create your packaging solutions.

Optimize the size

As mentioned, you'll want to make sure the weight of your custom box doesn't cost you more in shipping costs. Your packaging partner should ask you things about how much space you'll need in your packaging boxes and poly mailers, so they can work with you to maximize this space. Do you really need bubble wrap? Should you use corrugated packaging? These are all good questions to ask!

custom-size-and-weight-ecommerce-packaging

Personalization and customization of e commerce packaging

This is perhaps the "most fun" part of the packaging process. Successful ecommerce packaging leverages digital printing and professional graphic design to ensure their poly mailer and packaging boxes act as free advertising for their brand. Make sure to incorporate brand colors into the corrugated boxes! Think of this phase of the custom printing process as a chance to use your ecommerce packaging to improve brand loyalty.

You can add a logo, incorporate brand colors throughout the packaging, and add text wherever you'd like on the packaging.

Material selection and recyclability

You'll need to be extra careful when selecting corrugated boxes and poly mailers for your commerce packaging. All of your packaging supplies and packaging solutions should be environmentally conscious. Tyvek envelopes may be ultra durable and puncture resistant, but is this type of commerce packaging necessary for every product you sell? Don't forget to focus on sustainability as you think about printing: should you use digital printing or printing plates? How big do your shipping boxes and commerce packaging really need to be?

Get started with CarePac

As you can see, thoughtful and strategic packaging is essential for the success of your brand. Integrating sustainability into your packaging practices is as important as it's ever been, as customers expect a certain level of environmental responsibility from the brands they trust. We encourage all ecommerce businesses to prioritize the customer experience and environmental responsibility in their packaging choices.

At Carepac, we have decades of experience working with companies of all sizes to create the packaging of their dreams. Contact us today to learn more about our customization, design, and printing process.

Overwhelmed with

all the options?

Sustainable Packaging

Recyclable Packaging

$0.00

Cart

No products in the cart.

Recyclable Packaging

Seven Recyclable Packaging Options to Consider For Your Business

When it comes to keeping your brand current with your customers, one area you need to focus on is your eco friendly packaging options, including compostable packaging, reusable packaging, and sustainable packaging. As climate change continues to impact our everyday lives, many consumers avoid using products that don't come in sustainable packaging and prefer to reduce plastic waste throughout the supply chain and life cycle of their product.

In this blog, we'll discuss the different eco friendly packaging materials companies should consider providing to their consumers, along with a few tips for how you can promote a lower carbon footprint. Whether you opt for compostable packaging, reusable packaging, or some other kind of eco friendly packaging, we're proud your brand is taking the next step in packaging sustainability.

Popular Recyclable Packaging Materials

If you're curious about what your options are for sustainable packaging materials, we'll highlight some of the most common used by companies below. Just remember: when it comes to environmentally friendly packaging, any step your brand and your consumers can take towards reducing single use plastic packaging is a step in the right (and sustainable) direction.

Boxes with gummed paper tape

If your business is currently using boxes with plastic packaging tape, did you know that technically you cannot recycle paper and plastic together? You can improve your packaging sustainability by opting for gummed paper tape instead of plastic tape. Since all parts of the package are made from paper, they are really easy to recycle. If your business wants to focus on sustainable shipping, using this method and then using climate credits to offset the carbon footprint created by your business should be considered.

Kraft paper mailers

Using Kraft paper mailers is sustainable packaging 101. Since these packaging solutions are made out of regular paper, using them to send things to your customers can have a positive, collective impact on the environment. Businesses that use Kraft mailers for shipping products to customers include fast fashion, online shopping retailers, and large businesses that send a lot of contracts or paper products in the mail. In addition to Kraft paper, you can also look into using compostable mailers for shipping products.

Crinkle paper

If you currently use plastic or bubble wrap to pad your corrugated boxes, consider switching to biodegradable packing peanuts or crinkle paper. Both are considered to be an eco friendly packaging material, and they'll reduce the environmental footprint of your business. Natural resources, like beechwood trees and similar raw material, are dwindling, so any time you can use biodegradable or compostable packaging is an opportunity you should take advantage of.

Biaxially Oriented Polyethylene Film (BOPE)

The need for more environmentally friendly packaging intersects perfectly with the high-quality recyclable options that biaxially oriented polyethylene film pouches offer. BOPE is a clear material with two layers of oriented and processed Polyethylene. Printable, and convertible into Stand up pouches, and box bottom bags, this film is an environmentally friendly packaging option that may be accepted in municipal and commercial recycling programs.

Recycled packaging

Think outside the box and use recycled packaging materials in lieu of plastics when shipping items to customers. For example, skip the plastic packing peanuts and use paper you shred yourself. Businesses around the world struggle with paper waste -- why not get your office papers professionally shredded, keep the bags of shredded paper, and use them to line boxes or produce bags? Customers will be sure to appreciate that they're working with a sustainable business.

Cornstarch and mushroom packaging

Cornstarch and mushroom packaging are the newest eco friendly packaging option to hit the environmentally friendly packaging industry, and both are perfect examples of sustainable packaging solutions. Both are considered to be biodegradable packaging, since they can be broken down in a commercial or home compost environment, similar to regular paper. If your goal is to keep plastics out of the landfill, this flexible packaging option is among the best.

Cellulose packaging

Popular among a large portion of food brands, cellulose packaging is made from natural and sustainable sources like hemp, wood, and cotton. This packaging material is biodegradable, making it the perfect sustainable packaging alternative to plastic.

CarePac: Your Eco Friendly Packaging Partner

If your search for sustainable packaging has brought you to CarePac, we're honored that you'd consider us to be your eco friendly packaging partner. Our business model focuses exclusively on packaging, and we're making a huge push for more of our boxes and bags to use biodegradable, recyclable, and sustainable materials. If sustainability of the packaging industry is on your mind, you can rest assured that it's on our mind, too.

Overwhelmed with

all the options?