Key question
How does packaging move safely from design to production?
There are many steps between concept and shelf: mock-up, structural dummy, proof, press proof, and sign-off. Each step reveals errors that would otherwise prove costly later on. Effective production planning keeps both deadlines and budgets on track.
Learning objective: You can distinguish between the prototype and testing phases of packaging, identify cost drivers, and work backwards from the delivery date to create a timeline.
Every check is cheaper than a misprint.
8.1 / From mock-up to sign-off
Check before it gets expensive.
Four inspection steps lead from design to production:
01
Mock-up
Built model made of laser prints and cardboard to check the effect and proportions.
02
White sample
Unprinted sample made from the original cardboard, die-cut and creased.
03
Digital proof and press proof
Colour-accurate proof or print on the original material for colour checking.
04
Approval
Written confirmation that data, colours, and details are correct.
A proof is a colour-accurate test print, usually digital. A press proof is produced directly on the printing press using the original materials. The more variations and the larger the print run, the more critical these steps become.
Approvals must always be in writing.
8.2 / Costs and Schedule
Print run, format and finishing determine the price.
Packaging costs are primarily driven by the cutting die, printing plates, material, finishing, and run size. Fixed costs, such as the cutting die, are spread over many units with a larger print run. Producing multiple variants using the same cutting die delivers significant savings.
For small print runs, digital printing is often cheaper because printing plates aren't required. Printing, die-cutting and gluing still take time, though; allow for a buffer and ask the printers early about their production slots.
One cutting die for all varieties saves money.
8.3 / Planning backwards
From delivery date to start date.
A production schedule is calculated backwards from the fixed delivery date: delivery, finishing, printing, sign-off, proof, final artwork, design. This way, you can see the latest point at which each decision needs to be made.
Plan approvals and review cycles realistically, as this is where most delays occur. A buffer of around ten per cent protects against surprises.
Plan backwards to arrive on time.
Exercise
Prototype and plan
Task: Build a mock-up of a variety of 'Alpenkraut' and create the production schedule.
STEP 1
Print your design at 1:1 scale onto the net and build the mock-up.
STEP 2
Check the fit, readability, and colours, and note down any corrections.
STEP 3
Create the schedule up to the delivery date in the tool.
STEP 4
Formulate a short sign-off checklist for ‘Alpenkraut’.
Evaluation: Would you sign off on this packaging for printing with a clear conscience?
Final project
One line for three varieties.
In the final project, you will develop a packaging line for the three "Alpenkraut" varieties: peppermint, lemon balm and mountain herbs. You will bring together everything from the course: function, branding, structural design, materials, surfaces, mandatory information and production.
STEP 1
Job specification
Define functions, sales points, packaging levels and materials with justification.
STEP 2
Cutting die
Design a folding carton and set it up as a dieline with cutting and creasing lines.
STEP 3
Surface design
Design the primary display panel, reverse, and variant system for three varieties.
STEP 4
Mandatory information
Place all mandatory information, barcode, and disposal instructions legibly.
STEP 5
Prototype
Built mock-ups, production schedule and presentation of the full line.
Evaluation criteria: Function and protection (20%), shelf impact and variant system (25%), construction and die-cut form (20%), mandatory information and legibility (15%), prototype, schedule and presentation (20%).
All together, this makes up a package.