Things to Know Before Ordering Product Packaging

Packaging spans materials, structural layers, print methods, and production steps that control how a product is contained, protected, identified, and shipped. Manufacturers in the US rely on these details to match protection, cost targets, and retail or e‑commerce demands.

Primary, secondary, and tertiary layers carry different loads. Substrates such as paperboard, corrugated board, plastics, glass, and metals add barrier and mechanical traits. Print processes change color accuracy and run economics. Production moves through structural design, artwork preparation, tooling, printing, converting, and QC checks. Lead times change with dieline complexity, plate count, and finishing steps. Costs split across material area, print setup, finishing passes, tooling, labor, and freight. These factors set unit price and supply‑chain timing for custom boxes, pouches, or shipping containers. A supplier confirms dimensions, substrate grade, print method, finishing layers, tooling terms, proof type, and quantity before accepting an order, so the ordering process locks all specifications at the start of the run.

What is Packaging? 

Packaging is the engineered system of materials (paperboard, film, glass) and structures (folded cartons, pouches, corrugated trays) that contain, protect, identify, and facilitate handling of a product. It exists in three layers: primary (contacts product; examples: bottles, sachets), secondary (groups or presents retail units; examples: folding cartons, sleeves), and tertiary (enables transport and storage; examples: corrugated shipping boxes, pallets).

What are the Different Types of Packaging?

Packaging divides into three functional layers and multiple types defined by purpose, material, and form.

• Primary packaging: immediate product-contact container (examples: bottles, sachets, blister packs).
• Secondary packaging: unit grouping or presentation layer that bundles primary units (examples: folding cartons, sleeves, multipacks).
• Tertiary packaging: transport and storage protection used for distribution (examples: corrugated shipping boxes, stretch-wrap, pallets).
• Retail-ready packaging: shelf-display format that doubles as transport pack (examples: pre-glued trays, shippers with removable lids).
• E-commerce packaging: single-item shipping format designed for dimensional efficiency and drop resistance (examples: mailers with void-fill, tuck-top mail boxes).
• Frustration-free packaging: easy-open consumer packaging that removes excess materials and tools (examples: simple fold cartons, peelable seals).
• Bulk packaging: large-volume containment for raw or semi-finished goods (examples: Gaylord boxes, bulk bags, intermediate bulk containers).
• Standard packaging: off-the-shelf formats with fixed dielines and short lead times (examples: standard corrugated RSC, stock folding cartons).
• Custom packaging: specifies product‑matched dimensions, grade, and artwork so brands fix logos, regulatory text, and variable data on a dedicated dieline.
• Sustainable packaging: materials and constructions chosen for recyclability, recycled content, or compostability (examples: mono-material paperboard, PCR plastic, molded pulp).
• Paper-based packaging: cellulose substrates used for printing and structural support (examples: SBS folding cartons, corrugated board, molded pulp).
• Plastic packaging: thermoplastic containers and films chosen for moisture or chemical resistance (examples: PET bottles, PE bags, multilayer pouches).
• Glass packaging: inert, impermeable containers for long shelf life or premium perception (examples: beverage bottles, jars).
• Metal packaging: rigid or foil-based containers providing barrier and mechanical strength (examples: tinplate cans, aluminum foil laminates).
• Flexible packaging: film-based pouches and bags that reduce material use and weight (examples: stand-up pouches, flow-wraps).
• Rigid packaging: form-stable containers and trays for protection and presentation (examples: thermoformed trays, injection-molded jars, rigid telescoping boxes).

Select types by layer (primary/secondary/tertiary), by purpose (retail, e‑commerce, bulk), and by material/form (paper, plastic, glass, metal; flexible vs. rigid) to match protection, print needs, and end‑of‑life claims.

What is the History of Packaging?

Packaging history tracks shifts in material science, print processes, and distribution. Five technology phases altered containment and the way manufacturers specify protection, graphics, and compliance across product categories.

1. Preindustrial containment: Leaves, woven baskets, clay amphorae, and wooden boxes carried grains, oils, and liquids. Amphorae stored wine or oil for long routes. Wood crates held hardware or ceramics during inland trade.
2. Early industrialization (18th–19th centuries): Metal cans, cast glass, and machine-made paper increased shelf stability. The 1810 tin can patent fixed thermal processing steps. Lithographic plates pushed color consistency into mass production.
3. Mass packaging and corrugation (late 19th–early 20th centuries): Corrugated flutes and folded board reduced breakage and freight weight. Standard RSC footprints reduced variability during stacking in rail and warehouse systems.
4. Polymer and laminate era (mid‑20th century): PE, PP, and PET reshaped barrier behavior. Multilayer films with 30–150 micron structures controlled oxygen and moisture transfer. Heat seals replaced mechanical closures in many formats.
5. Digital, regulatory, and sustainability era (late 20th century–present): Digital print shortened runs to the hundreds. EVOH and aluminum layers raised recycling limits. Food-contact migration testing shifted from optional to routine in many markets.

Each phase changed how producers judge protection, cost, and recyclability. Material choice now interacts with plate requirements, color tolerances, and end‑of‑life claims; these patterns explain why substrate grade, print method, and compliance remain the largest procurement levers across carton, corrugated, and flexible packs.

What are the Different Types of Packaging Materials?

Packaging materials include paperboard, corrugated board, plastics, glass, metal, multilayer laminates, and cushioning substrates such as molded pulp or foams.

Paperboard

Paperboard is a cellulose-based sheet used for printable, folded cartons. Types include solid bleached sulfate (SBS), folding boxboard (FBB), and coated recycled board (CCNB) (examples: folding cartons, cosmetic boxes). Typical basis weights range from 200 to 400 gsm. Typical thicknesses run about 0.25–0.60 mm. SBS gives a bright, coated surface suited to high-resolution litho printing. CCNB and recycled grades trade whiteness for lower cost. Paperboard absorbs moisture, so add lamination or barrier coatings if humidity or grease are present.

Corrugated board

Corrugated board is a multi-ply laminated construction of liners and fluted medium. Flute profiles by nominal height: A ≈4.7–5.5 mm, B ≈2.0–3.2 mm, C ≈3.2–3.8 mm, E ≈1.1–1.7 mm. Use single-wall, double-wall, or triple-wall constructions for higher loads. Compression performance is measured by the Edge Crush Test (ECT) and the Box Compression Test (BCT). Select an ECT/BCT rating that matches expected stacking and distribution loads.

Plastics

Thermoplastics provide clarity, chemical resistance, and low oxygen permeability when multilayered. Common rigid resins include PET, HDPE, and PP (examples: bottles, jars, tubs). Flexible films commonly combine PET, BOPP, PA, and PE (examples: stand-up pouches, flow-wraps). Film thickness is measured in microns (µm). Typical flexible pouches run 30–150 µm depending on barrier needs. Recycled-content variants such as rPET and PCR-HDPE reduce virgin polymer use but may alter mechanical and visual properties.

Glass

Glass is inert and impermeable, so it preserves flavor and chemical stability and supports long shelf life. The density of glass is about 2.5 g/cm3, which increases freight weight and breakage risk. Add molded pulp or foam inserts to reduce transit damage. Glass is widely recyclable via curbside and closed-loop remelt programs. Consider reuse or refill systems to lower lifecycle impact when transport logistics permit.

Metal

Metal packaging includes aluminum and tinplate, such as beverage cans, food cans, foil laminates, and metal tubes. Aluminum foil laminates provide a near-zero oxygen barrier and strong moisture resistance. Tinplate provides rigidity and impact resistance for canned goods. Metal layers require corrosion protection and validated seals. Specify internal lacquer or epoxy linings if the product is acidic, and require seam-strength and leak tests during quality control.

Multilayer Laminates and Barrier Measures

Laminates combine films and foils to meet the target Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR). Common barrier layers include EVOH for oxygen control and aluminum for a near-total barrier. Lamination and coating choices affect recyclability. Full-material separation simplifies recycling, while incompatible laminates often require industrial recovery processes.

Inserts, Cushioning, and Specialty Substrates

Inserts position and protect product; options include die-cut paperboard, molded pulp (examples: egg trays, cushioning trays), EPE/EVA foam, and thermoformed trays. For electronics and sensitive components, ESD-safe foams and conductive materials prevent electrostatic discharge. Injection-molded trays and rigid foam inserts provide repeatable fit and high perceived value for premium products.

Which Printing Methods are Used for Packaging?

Packaging uses digital, offset, flexographic, gravure, and screen processes to print graphics on paperboard, corrugated board, films, metals, and glass.

Digital printing

Digital printing is best for short runs, rapid proofing, and variable data. It requires no plates. It is economically viable under ~5,000 units for many carton sizes. It works on coated and uncoated paperboard, some film laminates, and label stocks. Typical strengths: fast turnaround, easy versioning, and minimal makeready waste. Trade-offs: higher per-unit ink cost and fewer specialty-ink options versus plate processes.

Offset lithography

Offset lithography provides high-resolution, repeatable color for medium-to-high volumes. It requires a printing plate per color. Cost amortizes over runs from ≈1,000 to 100,000+ units. Best on SBS or FBB paperboard and coated substrates used in folding cartons. Strengths: tight register, fine halftone and photographic detail, and low ink cost at scale. Use spot inks (Pantone) for critical brand matches. Expect standard prepress and plate lead time.

Flexography

Flexography prints at high speed on corrugated liners, film webs, and flexible pouches. It uses photopolymer plates and runs on rotary web or sheet-fed presses. Typical applications: corrugated boxes, bag and pouch webs, and high-speed label lines. Strengths: efficient for long web runs and wide substrates, and lower plate cost versus gravure. Trade-offs: broader color tolerance and coarser halftone compared with offset.

Gravure

Gravure delivers continuous-tone quality and the lowest per-unit ink cost for very large runs. It uses engraved metal cylinders with high upfront cost. Typical use: film laminates, long-run flexible packaging, and publication printing. Economies appear at hundreds of thousands of linear meters or equivalent unit counts. Strengths: superior color consistency across long runs and fine screening. Weakness: long setup and cylinder amortization requirement.

Screen printing

Screen printing deposits thick ink layers for tactile, metallic, and opaque effects. It suits labels, specialty displays, and decoration on glass, metal, and rigid plastics. Strengths: heavy ink laydown, textured varnishes, and opaque whites on dark substrates. Trade-offs: slower per-color throughput and higher per-color cost. Best for short to medium specialty runs where effect matters more than speed.

Pick digital for short runs and variable content. Choose offset for high-fidelity litho on paperboard. Select flexo for corrugated and continuous-web film. Use gravure for ultra-high-volume laminates. Use the screen for specialty tactile or metallic effects. Match proofs and Delta‑E criteria to reduce rework and color disputes.

What are the Types of Packaging Finishes?

Packaging finishes include lamination, aqueous coating, UV coating, metallic decoration, embossing or debossing, and perforations that change surface protection, gloss level, tactile detail, or opening behavior.

Lamination (film)

Lamination applies a thin BOPP (biaxially oriented polypropylene), PET (polyethylene terephthalate), or nylon film to the printed board to raise scuff resistance and moisture stability. Matte, gloss, and soft‑touch films vary in friction and reflectivity. Film thickness of 12–25 microns is common for folding cartons. Use lamination on cartons that see repeated handling or friction during transport.

Aqueous coating

Aqueous coating forms a water‑based protective layer that dries fast on litho‑printed board. It lowers rub marks and gives semi‑gloss or matte effects without trapping odors. Typical coat weights fall around 1–3 gsm (grams per square meter). It suits food and personal‑care packs that require low‑odor protection.

UV coating

UV coating cures under ultraviolet lamps and yields a hard, glossy surface. Spot UV applies the gloss only to selected artwork, such as logos or product names. Coating builds a thicker layer than aqueous methods and raises scratch resistance. It works on Solid Bleached Sulfate (SBS) and Folding Boxboard (FBB), and some films with proper surface treatment.

Metallic decoration

Metallic decoration uses foil stamping, cold foil, or metallic inks to create reflective surfaces. Foil stamping applies a metal layer with heat and pressure; cold foil transfers metallic pigment during printing. Metallic inks carry aluminum flakes that reflect light without a separate foil step. Use metallic decoration for brand marks, borders, or security accents.

Embossing and debossing

Embossing raises selected areas of the board while debossing presses artwork into the sheet. These dies create depth variations of about 0.15–0.50 mm (millimeters). These processes add tactile cues and help anchor spot foil or spot UV. They require precise registration and may influence fold lines if placed near creases.

Perforations and tear notches

Perforations create controlled tear lines for opening trays, mailers, or wrap‑around cartons. Hole patterns vary by pitch and type (micro‑perf, macro‑perf). Tear notches weaken a local area of film or board to start opening. Both features support e‑commerce frust‑free formats and retail multipacks that need quick access without tools.

How Does Packaging Design Affect Performance and User Handling?

Packaging design changes protection, grip, opening behavior, pack stability, and assembly time, because structure, tolerances, closure geometry, and ergonomic cues control how a user lifts, opens, and returns a product. The same dieline produces different outcomes when panel stiffness, crease ratios, or perforation pitch shift by a few millimeters.

Design influences four measurable areas: load transfer, motion restraint, opening force, and ergonomic contact. Load transfer depends on board grade and crease compression. Motion restraint depends on insert depth and sidewall angle. Opening force depends on the perforation pattern and the closure friction. Ergonomics depend on thumb access, tab geometry, and surface friction.

• Protection: Panel stiffness, crease durability, and insert fit change how cartons resist compression or impact (examples: tight-tolerance cavities for electronics, scored corners for glass). Over-sized internal volume increases product movement and raises drop‑failure rates.
• Handling: Tab length, cut depth, and friction surfaces alter the force needed for opening (examples: 2–3 mm thumb notches on tuck flaps, 10–15% lower tear force from micro‑perfs). Surfaces with matte film reduce slip during single-hand use.
• Identification: Layout of panels, display windows, and print-safe zones determines how users orient the pack. Die-cut windows expose color references, if used for cosmetics or FMCG multipacks.
• Assembly and closure: Locking features change assembly time by measurable margins (examples: auto-lock bottoms reduce manual folding steps). Glue-flap width changes bond reliability, and warped edges influence machine feed.
• Reuse and disposal: Tear paths, recycle marks, and mono-material structures influence how users flatten or separate components after use (examples: clean fiber recovery from unlaminated SBS cartons).

Performance and user handling sit upstream of structural specification. The structural model sets dimensional tolerances and crease positions; design details then adjust how users interact with the pack during opening, carrying, and disposal.

How Should a Structural Design be Specified to Ensure Fit and Protection?

Specify internal and external dimensions, tolerances, closure type, and handling features with the product geometry so designers can create a correct dieline and prototype. Use exact product measurements with defined tolerance bands (examples: length × width × height with ±1–3 mm). Mark protrusions and fragile zones. State the clearance required for inserts (examples: 2–5 mm for rigid items, more for compressible goods). Use CAD or 3D models for complex shapes to prevent interference during assembly.

Structural choices such as tuck end, auto‑lock bottom, sleeve, or telescoping rigid box change machine feed and consistency. Auto‑lock bottoms reduce manual folding steps but reduce usable inner height. Telescoping two‑piece rigid boxes add extra material and assembly cost. For e‑commerce, use single‑item layouts with internal bracing to restrict movement and reduce empty volume to control dimensional‑weight charges.

What are the Standard Production Steps for Packaging?

The standard production steps for packaging follow a fixed technical sequence that controls accuracy, material use, and run timing. Each stage links structural design, artwork preparation, tooling, printing, converting, and quality checks.

1. Brief and Product Data Collection

Teams gather product geometry, internal and external dimensions, regulatory notes, and run‑length targets. They record substrate class, color expectations, and finishing needs. Examples include SBS (Solid Bleached Sulfate) vs. FBB (Folding Boxboard) grades for cartons or E‑flute vs. B‑flute for corrugated.

2. Structural Engineering and Dieline Creation

Engineers create a dieline with cut, crease, and glue markers. They test fit with prototypes and verify tolerance bands of ±1–3 mm. They confirm clearance for inserts if units contain molded pulp, foam, or thermoformed trays.

3. Artwork Prepress

Prepress teams convert files to print-ready PDFs with bleeds, outlined fonts, and safe zones of 2–4 mm (millimeters). They separate CMYK and spot colors. They prepare varnish, foil, and emboss layers. They verify barcode magnification and quiet zones.

4. Proofing and Approval

Digital proofs validate color, panel alignment, and trim. Physical proofs or press samples confirm texture, coating, lamination, and registration. Approval cycles add days if spot colors or metallic layers appear.

5. Tooling Fabrication

Die-makers create steel rule dies, crease matrices, emboss plates, and print plates for offset or flexo. Custom shapes or multi-level emboss plates add lead time. Corrugated runs often require lower-cost die boards than folding cartons.

6. Printing and Coating

Press operators run digital, offset, flexo, or gravure, depending on volume and substrate. They apply aqueous, UV, or film coatings. They monitor density and Delta‑E targets to control color drift across sheets or webs.

7. Converting: Die‑Cutting, Folding, and Gluing

Sheets pass through cutting and creasing. Auto‑lock bottoms, crash‑lock features, and glued sidewalls form final shapes. Inserts are cut and assembled. Accuracy in fold angles and glue-flap width prevents feed problems during packing.

8. Quality Control and Dimensional Checks

Inspectors measure external and internal dimensions and compare against approved dielines. They test crease strength, adhesion, and surface finish. Examples include ECT (Edge Crush Test) checks for corrugated or peel-strength checks for seals.

9. Packing, Palletizing, and Dispatch

Completed units are stacked, banded, and palletized with orientation marks. Teams document batch codes, Quality Control (QC) results, and carton counts. Freight scheduling follows weight and volume calculations.

What are the Typical Lead Times for Packaging Orders?

Typical lead times range from a few days for stock formats to 2–6 weeks for custom cartons, because each packaging order passes through data collection, structural design, prepress, proofing, tooling, printing, converting, and inspection.

Lead time shifts with substrate class, plate requirements, finishing layers, and freight distance. Custom dielines extend schedules if embossing plates or foil tools are included. Digital runs compress timing because no plates are created.

• Stock items: pre-cut or pre-glued units ship in 2–5 days (examples: RSC shippers, standard mailers).
• Corrugated runs: simple dies finish in 7–14 days; flute type and print plate count affect timing (examples: B‑flute shippers, E‑flute retail trays).
• Folding cartons: SBS or FBB with offset print, film lamination, or foil stamping require 14–42 days, if approvals arrive promptly.
• Flexible packs: gravure or long-run flexo webs require cylinder or plate preparation that adds 10–21 days before production.

Total duration depends on approval cycles, proof changes, plate fabrication, and volume. Freight time adds separate days based on origin. Long runs with multi-step finishing stack time at each machine, so plan lead time with contingency for color adjustments or QC rechecks.

How do Packaging Costs Break Down?

Packaging cost breaks down into material use, print setup, finishing steps, tooling, labor, inspection, and freight. Each part changes the total landed cost because substrate grade, ink count, and machine passes vary by carton or corrugated style.

• Material use covers sheet area, gsm grade, or flute type for board examples such as 250–400 gsm SBS or B‑flute liners.
• Print setup covers digital click charges or plate creation and ink density across CMYK or spot inks.
• Finishing steps cover lamination films, aqueous or UV coats, foil zones, and emboss depth.
• Tooling charges cover steel rule dies, crease matrices, and foil blocks that amortize across the run.
• Labor time covers makeready sheets, press calibration, die‑cutting, folding, and gluing.
• Inspection and freight cover QC checks, pallet prep, dimensional weight, and route distance.

Material area and color count create the largest swings. Thin board, fewer colors, or fewer finishing passes reduce cost. Larger runs spread the die cost across more units and stabilize the per‑unit price.

How can the Packaging Unit Price be Estimated?

Packaging unit price is calculated by isolating material area, print method, finishing layers, tooling charges, labor time, and freight, then dividing the total cost by run quantity. Each variable changes with dieline size, color count, substrate grade, and approval cycles.

Accurate estimates depend on measurable inputs: sheet area in square centimeters, GSM or flute type, CMYK or spot color plates, lamination or coating weight, die and emboss plate cost, makeready waste, and palletized freight distance. Price shifts as runs cross break‑even thresholds for digital, offset, or flexo processes, because fixed setup cost spreads across more units.

• Material area relies on dieline dimensions and substrate grade (examples: 250–400 gsm SBS sheets, B‑flute liners).
• Color count uses CMYK or spot inks; printing plates create upfront setup charges in offset or flexo.
• Finishing layers add film lamination, aqueous or UV coats, foil zones, or emboss dies that change sheet passes.
• Tooling cost covers steel rule dies, emboss plates, or foil blocks; amortization drops as run quantity rises.
• Labor and makeready reflect press setup time, calibration sheets, and converting steps (die‑cutting, folding, gluing).
• Freight reflects pallet count, dimensional weight, and route distance.

Typical folding‑carton example: a 20,000‑unit run aligns near material $0.15, printing $0.05, finishing $0.03, tooling amortization $0.03, labor $0.01, and freight $0.04 → ≈$0.31 per unit. Reduce color count or remove metallic layers to lower setup cost; switch to digital only if run volume falls below offset break‑even thresholds.

What is Packaging Technology?

Packaging technology covers the materials, forming steps, sealing systems, and print processes that build protective retail or transport units. It links substrate grade, barrier level, tooling, and converting stages. Teams set film thickness, flute height, heat‑seal values, crease patterns, and color targets. These factors fix shelf stability, machine flow, and shipping reliability across different load paths.

• Materials: Paperboard, corrugated flutes, PE films, PET films, and aluminum layers with defined OTR and WVTR examples.
• Sealing systems: Heat‑seal jaws, crimp bars, mechanical closures, and adhesives with peel‑strength checks.
• Print methods: Digital, offset, flexo, gravure, and screen processes with run‑length thresholds and Delta‑E targets.
• Conversion steps: Die‑cutting, creasing, forming, and gluing with tolerance bands of ±1–3 mm.

How Does Packaging Function in Marketing?

Packaging in marketing sets product identification, brand cues, and compliance text at the point of sale. Folded‑panel layout, color contrast, and tactile coatings build recognition in crowded aisles. Labels, panels, and windows fix claims, instructions, and batch information. Teams hold color builds, safe zones, and barcode positions to keep scan accuracy and shelf clarity across runs.

• Brand cues: Spot colors, foil accents, and embossed zones on primary panels.
• Category signals: Panel hierarchy for ingredients, claims, and use steps.
• Regulatory text: Net weight, warnings, and date codes in compliant zones.
• Shelf behavior: Front‑panel proportions that maintain visibility in vertical or horizontal facing.

What is Custom Packaging?

Custom packaging means a product‑specific structure, material grade, and artwork layout built from a dedicated dieline. It fixes internal fit, external dimensions, substrate grade, color layers, and finishing steps so the pack matches product geometry and regulatory text. Custom packaging changes four technical areas: structural clearance, board weight or film construction, print method, and finishing sequence.

Structural fit depends on length, width, height, and tolerance bands that match the product shape. Material selection sets stiffness, barrier behavior, and compression strength. Color layers and varnish or foil zones define branding, data placement, and compliance panels. Finishing steps, such as lamination or embossing, modify scuff resistance and surface texture. These linked settings create consistent protection, machine flow, and retail clarity across full production runs.

How to Order Custom Packaging?

Ordering custom packaging requires a fixed sequence of confirmations that lock dimensions, material grade, print method, finishing steps, tooling terms, and acceptance checks. This sequence prevents design drift and late corrections across structural, artwork, and production stages.

1. Define fit data: Capture internal and external dimensions with ±1–3 mm tolerance bands and record fragile zones on the product.
2. Confirm quantity: Set the planned run length, safety stock, and batch splits for production scheduling.
3. Select substrate: Specify SBS, FBB, CCNB, E‑flute, B‑flute, or film laminates with recycled‑content percentages where required.
4. Fix print method: Choose digital for small runs, offset for litho quality on cartons, or flexo for corrugated and film webs.
5. Specify finishing: List lamination film type, coating weight, foil zones, and emboss depth to prevent misalignment during converting.
6. Approve tooling: Record die dimensions, crease matrix setup, and foil block geometry; confirm ownership and amortization terms.
7. Set proof type: Request digital proofs or press samples with color targets and barcode magnification checks.
8. Define acceptance checks: Document mechanical, barrier, and color tolerances with pass/fail levels for QC.
9. Set logistics terms: Provide pallet pattern, carton count, orientation marks, and delivery terms.

Packaging orders proceed cleanly when structural data, artwork layers, color builds, and coating specifications appear in one consolidated specification sheet. This approach anchors supplier expectations, reduces remake risk, and stabilizes landed cost across future reprints.

Which Decisions Must Be Finalized Before Placing an Order?

Finalize functional requirements, material grade, run quantity, print method, finishing, and acceptance criteria before issuing a purchase order.

• Dimensions: Final external and internal dimensions with tolerance bands.
• Quantity: Exact run length and reserve (examples: planned run plus safety stock percentage).
• Substrate: Specific paperboard grade or film construction and any recycled-content requirements.
• Print and finish: Color model (CMYK or spot), varnish/lamination choices, and emboss or foil requirements.
• Tooling: Die specifications and ownership (customer-supplied or manufacturer-supplied) and amortization expectations.
• Proofing: Type of proof required (digital proof, press proof, or physical sample) and approval workflow.
• Acceptance tests: Mechanical, barrier, and color tolerances with pass/fail criteria.
• Logistics: Delivery terms, palletization scheme, and incoterms.