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Offset Printing

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Offset Printing

The manufacturing process for offset printed boxes using 4-color (CMYK) and 5-color (CMYK + Pantone) printing involves several steps to ensure high-quality, vibrant, and accurate results.

As one of leading custom paper box manufacturers, Packart Innovation packing Solution team offer different kinds of custom paper boxes customized on paper box material, paper box printing, paper box printing finish, paper box styles, and paper box packing.

The paper box widely applied in cosmetic box packaging, soapbox packaging, perfume box packaging, cake box packaging, pizza box packaging, food box packaging, take away box packaging, medical and pharmacy box packaging, software box packaging and small gift packaging.

 

Manufacturing Process for Offset Printed Corrugated Boxes

Moreover, some customer calls them custom printed boxes, custom packaging boxes, and custom paper boxes.

Design and Prepress Preparation

Artwork Creation: Design is created with software like Adobe Illustrator, Photoshop, or CorelDRAW.

Color Management:

  • CMYK for full-color images.
  • Pantone Colors (PMS) for precise spot colors or branding consistency.

Offset Printing Process

Since corrugated boards cannot directly go through offset printing machines due to their thickness and uneven surface, the process involves printing on a thin paper sheet first.

Offset Printing on Paper:

  • The design is printed on a high-quality paper sheet (e.g., art paper, kraft paper, or liner board).
  • Standard thickness: 100-170 gsm paper.

Litho-Lamination

  • Corrugated boards are made from layers: linerboard (outer layers) and fluted paper (middle).
  • Common types: E-flute, B-flute, or C-flute depending on strength and thickness requirements.

Mounting:

  • The printed paper is carefully mounted onto the corrugated surface using a litho-lamination machine.
  • The lamination process ensures the printed sheet adheres smoothly without wrinkles or bubbles.

Die-Cutting

  • Once the laminated corrugated boards are ready, they are fed into a die-cutting machine.
  • The machine cuts the material into the desired box shape with precise creases, slots, and folds.

Folding and Gluing

  • The box is folded along the die-cut crease lines.
  • Automatic gluing machines apply adhesive to join the panels and complete the box structure.

Corrugated Board Types:

  • E-Flute: Thin, lightweight, great for detailed printing.
  • B-Flute: Medium thickness for sturdier boxes.
  • C-Flute: Thicker and durable for heavy products.

Printed Sheets:

  • Art Paper (high-quality finish).
  • Kraft Paper (eco-friendly and rustic look).
  • Linerboard (white or brown sheets for mounting).

Finishing Touches

  • Special finishes can be added to enhance the box:

    • Spot UV Coating: Highlights specific areas (e.g., logos or text).
    • Foil Stamping: Adds metallic or shiny effects.
  • Embossing/Debossing: Creates raised or recessed designs for a premium feel.
  • Window Patching: Transparent windows for product visibility.

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