Here is a comprehensive guide that dives into various aspects of packaging design, terminology, materials, finishes, manufacturing processes, and supplier types. Packaging lingo can be another language. Here's some helpful terms ✌️ Let's explore the intricate world of packaging terms!
Design terms
Finishes and Decoration terms
Material terms
Types of packaging
Manufacturing terms
Supplier terms
Simplifying Design Terms
This post provides definitions and explanations of various design terms used in packaging, such as bleed, clamshell, cutter guide, die line, mock-up, Pantone Matching System (PMS), resolution, and substrate.
Bleed: Area beyond the cut edge where design elements extend to avoid white space.
CMYK: Cyan, Magenta, Yellow, and Black—color model used in printing.
Cutter guide: A drawing of a die cut for a piece of artwork showing size, shape and vital statistics for the artworking process.
Die Line: A template showing where cuts, folds, and creases are made on packaging material.
Mock-Up: Prototype of the packaging design for review.
Pantone Matching System (PMS): A standardized color system used in printing to ensure consistent color across packaging.
Plate(s): printing plate used in offset or flexographic printing. Multiple plates typically required for multicolor prints
Pre-Press: Preparing files for print production, ensuring quality and alignment.
Resolution: The clarity of artwork, measured in DPI.
Spot Color: Using a specific color or two to highlight brand identity in printing.
Substrate: Any base material that a design is printed onto: a carton, board, polypropylene, metallic film and so on.
Primary Packaging: Directly holds the product (e.g., bottles).
Secondary Packaging: Outer packaging to protect the product and/or that holds together multiple primary packages, like a cardboard box for bottled drinks.
Unboxing Experience: The sensory and visual experience a customer has when opening a product, often enhanced through custom branding and thoughtful design.
Enhancing Packaging Design with Finishes & Decoration
This section explores different finishes and decorations that can enhance packaging design, including aqueous coating, debossing, embossing, foil stamping, gloss finish, matte finish, soft-touch coating, spot UV, UV coating, and varnish.
Acid etching: A process that uses a strong acid to cut into another substance. When glassware is immersed in a bath of acid, for example, a smooth, frosted effect is created on the surface of the glass.
Applied color lettering (ACL): When colorful graphic or typographic elements are permanently fused onto the surface of a glass bottle.
Aqueous Coating: A water-based finish that provides protection and sheen, making it eco-friendly.
"Blind" Spot UV: Spot UV applied without color ink underneath, leaving only the clear gloss effect.
Debossing: Opposite of embossing, where the design is pressed into the surface for an indented effect.
Eco-Friendly Inks: Soy-based or water-based inks that reduce harmful environmental impact during printing.
Embossing: A raised design that adds texture and a premium feel.
Euroslot: A standardized slot shape, often found on packaging, designed to hang on retail display hooks.
Flexo printing: flexographic printing-High-speed, low cost, high volume printing method most commonly used for low color count packaging produced in high quantities.
Film: An unsupported, thin, flexible material no more than 0.01-inch thick that is applied to paper surfaces for a desired effect (matte, gloss) and protection.
Foil Stamping: Adding metallic foils (gold, silver, etc.) for a luxury appearance.
Gloss Finish: A shiny, reflective surface treatment that enhances colors and gives packaging a polished look.
Hot Stamping: Applying metallic or colored foils, typically for a luxury look.
Hang Tab: An adhesive or built-in tab added to packaging to enable hanging on retail pegs.
Header card: Either the backing piece of a card and plastic-style blister pack, or a board attached behind products that are hung by means of a euroslot.
J-Hook: A specific type of hook used in retail to hold hanging packages.
Laminate - Multi-layered materials for added strength and protection, can also be referred to as "film".
Litho or Offset printing: used for premium packaging, such as high-quality printed boxes, labels, and folding cartons. It’s especially common in retail packaging for cosmetics, electronics, and other consumer goods where sharp graphics and vibrant colors are important.
Matte Finish: A non-glossy, smooth surface that provides a subtle, elegant look.
Registration: Refers to the alignment of colors on a printed piece. Litho has the best registration.
Soft-Touch Coating: Creates a velvety, soft texture for an elevated sensory experience.
Silk Screen Printing: Used for directly printing on cylindrical packaging (e.g., bottles).
Spot UV: A method of applying a high-gloss finish to specific areas on the package for emphasis.
UV Coating: A protective coating that enhances durability and adds a high-gloss or matte effect.
Varnish: A clear coating applied to protect and enhance the surface, available in gloss, satin, or matte finishes.
Window patch - Transparent plastic added to a package to allow visibility of the product.
Zipper closure - A resealable closure typically used in flexible packaging.
Essential Materials for Your Project
Details various materials commonly used in packaging design, such as aluminum, biodegradable materials, corrugated cardboard, glass, paperboard, plastarch material (PSM), plastic (PET, HDPE, LDPE), polyethylene (PE), and polypropylene (PP).
Acrylic: Durable and glossy plastic, often used in luxury cosmetics.
Aluminum: Lightweight, used for cans and lids.
Biodegradable Materials: Eco-friendly options made from plant fibers, most commonly sugarcane or starches.
Blank: A box that is not yet folded and glued shut.
Box board (grey board) - Paperboard for constructing rigid boxes. A thinner piece of paper with printed graphics is wrapped over the box board to create the finished packaging.
Clamshell: This refers to the two hinged halves of a plastic shell that form protective packaging for small, valuable items such as electronics. Can also be made from other materials.
Corrugated Cardboard: Lightweight material used for shipping boxes.
Creep: The name given to the dimensional change over time of material under a heavy load. At room temperature 'creep' is sometimes called 'cold flow'.
Custom Inserts: Molded or cut inserts designed to secure and display products within a box.
Flute (corrugation): This refers to the ridges that are pressed into a sheet of material that has been softened by steam. The material is then sandwiched between flat sheets to form corrugated fibreboard.
Glass: Recyclable material for beverages and cosmetics.
Kraft Paper: Brown color,Eco-friendly, recyclable material used for wrapping and void fill. Can also be used on the exterior of product packaging.
Paperboard: Thin material most commonly used for retail packaging.
Plastarch Material (PSM): aka plant or potato starch material. A flexible packaging material, PSM is usually made from the starch found in corn or potatoes.
Plastic (PET, HDPE, LDPE): Versatile plastics for bottles and films.
Polyethylene (PE): A thermoplastic material composed of polymers of ethylene, PE is usually a tough, translucent solid that comes in low, medium and high density forms, and is popular as a container for frozen foods.
Polypropylene (PP): Available as a fibre, film or foam, in any colour or clear, PP is a super-versatile material formed from propylene polymers.
The Diversity of Packaging Types
Discusses different types of packaging, including blister packs, flexible packaging, header cards, primary packaging, secondary packaging, and tertiary packaging.
Active Packaging: Packaging designed to interact with the product, such as absorbing moisture or gases to extend shelf life.
Airless Pump: Dispensing system designed to protect skincare products from air exposure.
Blister pack: Refers to several types of pre-formed plastic packaging for small consumer goods. A blister pack consists of a web of 'blisters' or pockets made from plastic. Often used as unit-dose packaging for pharmaceutical tablets.
Compact: Packaging for pressed powders, often with a mirror and applicator.
Dropper Bottle: Used for precise application of serums or oils.
Flexible Packaging: Made of easily yielding materials like plastic, film, or foil, this type is widely used for food and beverage products.
Mailer Box: Sturdy corrugated boxes designed for shipping products directly to customers.
Padded Envelope: Envelopes lined with bubble wrap or foam to protect products during transit.
Primary Packaging: Directly holds the product (e.g., bottles).
Secondary Packaging: Outer packaging to protect the product and/or that holds together multiple primary packages, like a cardboard box for bottled drinks.
Tube: Flexible, squeezable packaging, common for lotions and gels.
Tertiary Packaging: Bulk handling (e.g., pallets).
Manufacturing Terminology
Defines manufacturing terms like acid etching, applied color lettering (ACL), blow molding, die cut, gatefold, injection molding, just-in-time (JIT), lean manufacturing, production line, quality control, supply chain, and thermoforming.
2-up: Two designs are printed side by side on one sheet, the size of sheet will depend on the printing machine bed size.
4-up: Four designs are printed on one sheet, the size of sheet will depend on the printing machine bed size.
Blank: A carton that has been cut and creased but not yet folded and glued shut. Also refers to the mould used to transform glass into a preliminary bottle shape.
Blow moulding: The process of forming a bottle by putting a hollow tube between two halves of a mould and blowing air into it, forcing the material to follow the shape of the mould.
Construction Sample is a prototype of packaging that is created to test its physical structure and functionality.
Die cut: Any operation in which a sharp-edged tool or blade is used to cut a shape, or hole, into a variety of substrates; or to cut a shape into a material that can't be achieved with a guillotine.
Digital Printing: Fast, versatile printing for small batch orders or customized packaging.
Flat-Pack: Packaging that can be assembled easily but ships flat to save space and shipping costs.
Gatefold: When paper or other material is folded inward to form four or more panels.
Injection Molding: Process for creating plastic containers.
Just-In-Time (JIT): An inventory strategy companies employ to increase efficiency and decrease waste by receiving goods only as they are needed in the production process.
Lean Manufacturing: A systematic method for the elimination of waste within a manufacturing system.
Litho or Offset Printing: High-quality print technique used on folding cartons and paperboard boxes.
Pack-Out: Final packaging process, including product assembly, labeling, and packing for shipment.
Production Line: A series of sequential steps in a manufacturing process where materials are processed to create a final product.
Quality Control (QC): Processes and procedures used to ensure that products meet specified quality standards.
Supply Chain: The network of individuals, organizations, resources, activities, and technology involved in the creation and sale of a product.
Thermoforming: A process of forming plastics by heating a plastic sheet to the point where it gets soft and pliable, and transforming it into the desired shaped using vacuum, pressure, and mechanical assists.
Exploring Different Types of Suppliers
Explores various types of suppliers in the packaging industry, including converters, manufacturers, distributors, contract packagers, and trading companies.
Converters: Modify raw materials for packaging but do not produce finished packaging.
Manufacturers: Companies that produce packaging materials and products, like corrugated boxes, plastic bottles, or flexible films.
Converters: Businesses that modify raw materials, such as printing or laminating, to create customized packaging solutions.
Distributors: Companies that source and supply packaging products from various manufacturers, often offering a wide range of materials.
Contract Packagers: Specialists who assemble, fill, and package products on behalf of a brand or company.
Trading Companies: Firms that source packaging products from various manufacturers (often overseas) to resell to local businesses.
Special Packaging
Aseptic Packaging: Sterilized packaging for food and pharmaceuticals.
Tamper-Evident Packaging: Shows signs of unauthorized access.
Other Helpful Terms Related to Packaging
Cushioning Materials: Foam, bubble wrap, or air pillows used to protect products from damage during shipment.
Dimensional Weight Pricing: Shipping cost calculation based on the dimensions of the packaging, not just its weight.
Minimalist Packaging: Reducing excess packaging materials to lower environmental impact and shipping costs.
Poly Mailer: Lightweight, waterproof envelopes made from polyethylene, ideal for soft goods like clothing.
Rigid Mailer: Flat, sturdy mailers used for documents, books, or flat products.
Returnable Packaging: Packaging designed to be easily used for returns, with resealable adhesive strips or tear-off sections.
Tab-Lock Mailer: A secure mailer with locking tabs, often used for small, lightweight items.
Void Fill: Materials like crinkle paper, air pillows, or foam used to protect products during shipping.