Specialty Coffee Expo&nbsp; Trusted Pouch Provider - &nbsp;CarePac

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Specialty Coffee Expo
Trusted Pouch Provider - CarePac

Speciality Coffee Expo (SCE) is the largest tradeshow that’s focused exclusively on America’s favorite beverage -- coffee! As a coffee packaging provider, our favorite part of the event is the coffee design awards for branding and packaging, but we might be a little biased. 😉

If you have your eyes on that prize, connect with us at the event to discuss your coffee packaging needs. Unlike other coffee packaging providers, we allow for full customization, from the bag size and material to branding. We work with coffee companies of all sizes to help them craft an aesthetically pleasing bag that’ll keep their beans as fresh as the day they were roasted.

Why CarePac?

Because we’re awesome. In all seriousness, though, we pride ourselves on being a small, family-owned and operated business that takes packaging as seriously as you take coffee. We live and breathe packaging, and all our products are proudly made in the USA. We strive to make every customer a repeat customer, and you’ll notice this as our helpful CareDesign team guides you through the process.

And when we say we work with companies of all sizes, we mean it. In fact, we offer prototyping as few as 100 units! This allows coffee brands, like yours, to test new blends or offer seasonal flavors without having to invest your entire packaging budget into a single style of bag.

Types of Coffee Pouches We Offer

Although we offer hundreds of different bag variations, we do offer specialty pouches that are catered specifically to coffee brands. Here are a few of the packaging options we recommend for our roster of clients in the coffee industry:

Box Bottom Bags

These bags have a square bottom, stand up on their own, and can be fully customized to represent your brand.

Side Gusseted Bags

Although this is an older pouch configuration, it’s extremely popular in the coffee industry for its versatility.

Quad Seal Bags

These are four-corner bags that have two premade side gussets that provide reinforcement so your product stands tall on shelves.

Other Customization Options

Let’s face it - the coffee industry is saturated with competition, and standing out often comes down to packaging. We offer a variety of customization options that can help take your packaging to the next level, including a variety of bag materials and finish options. Here are a few options to consider:

CareCompost with a zipper

For the eco-conscious consumer who prefers to buy coffee in bulk, the zipper helps keep things fresh while the environmentally friendly material allows them to compost their bag when they’re done with it.

CareVac

Whether your target market is the commercial food industry or doomsday preppers, our line of vacuum seal bags will keep your coffee fresh for as long as possible. Bonus: opt for lay flat pouches for easy storage.

Soft Touch or Metallic Effects

High-quality finishes like soft touch or metallic effects can encourage customers to pick up your product while browsing the crowded aisles at the grocery store.

Catch Us @ Specialty Coffee Expo

Want to hold and inspect our high-quality bags in person? Have questions about our customization process? Just want to say “hi”? You can catch us at the 2024 Specialty Coffee Expo!

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Coffee Pouch & Packaging FAQs

Can you provide examples of custom pouch designs you’ve created for other brands?

Yes, we will have examples available at the SCE, and here are a few visual examples as well.

What materials do you recommend for preserving coffee freshness, and can you customize them for our specific needs?

Our CareSilver and CareFoil materials are our highest barrier materials, meaning they’ll really keep your coffee fresh.

What is the typical lead time for designing and manufacturing custom coffee pouches?

CarePac offers a unique lead-time menu. Unlike some of our competitors (Roastar and ePac, to name two!), we offer total customization, from the size and material to the features included in your bag. As such, we have to plan our production more carefully than the companies that fit everyone into a few set sizes and use only one print method. Our fastest production lead time is 3 weeks.

Do you offer environmentally friendly packaging options, and are they suitable for coffee products?

Yes, we currently offer compostable and recyclable materials. While these are great options, they do have less of a barrier. As such, we recommend using these materials for small or seasonal batches.

Can you accommodate various sizes and shapes to match our coffee product range?

Yep! When we say “total customization”, we mean it. Unlike other companies that force you to fit your product into their bags, we create bags specifically for your product.

What printing and finishing options are available for customizing the appearance of our pouches?

Because we offer both plate and digital printing, we offer SO MANY finishing options, including glossy and matte. To learn more about our finishing options, check out our full range of options.

Do you have quality control measures in place to ensure consistent and durable pouches?

Yes. CarePac is ISO 9001:2015 certified, and we pride ourselves on adhering to these top management standards.

Are there minimum order quantities or volume discounts for custom pouch orders?

CarePac offers prototyping from 100 bags, meaning you aren’t tied to printing bags in extremely high numbers. (

Will CarePac be attending Specialty Coffee Expo? If so, what booth?

...

Are your bags manufactured in the US?

Yes, we’re extremely proud to be making pouches in the USA!

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Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Packaging Design

Understanding Color Reproduction on Flexible Materials

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Understanding Color Reproduction
on Flexible Materials

Ink dynamics is the study of how a wider range of inks behave and interact with certain materials. It's an important consideration and essential tool for an infinite number of graphic designers and color reproduction/color management professionals around the world. Since it directly impacts the quality of the final product, ensuring color accuracy and color temperature on the final product (after it has been printed) is essential.

Simply put, the visible spectrum of colors looks totally different in a digital image or color photography, on digital cameras, or on computer monitors than it does in real life, as things like reflected light, blue light, light sources (natural vs. fluorescent light) and exposure time can all impact how something looks. Spectral sensitivity and spectral power distribution can also impact the color balance in graphic arts.

As such, the study of color reproduction, color temperature, and color rendering is an essential aspect of quality control. This is usually referred to, generally, as color management.

The basics of ink dynamics

When it comes to ink dynamics and understanding its impact on color reproduction, there are a few different things to consider, including ink properties, interaction with flexible materials, and external and environmental factors that can influence ink behavior. We'll discuss each of these, and its impact on color perception and color rendition, below.

Ink properties

Ink is more than just ink: it's made up of pigments, resins, additives, and solvents. Each of these plays a critical role in determining how an ink dries on different materials and how it will display an entire range of color once dried.

It's important to note that the human eye sees things different in real life than it does on different devices, like like a computer monitor, so understanding how to make an easy adjustment to account for this is key.

Interaction with flexible materials

Different kinds of materials interact with inks different. For example, the color appearance of RGB values will look different on plastics as they do on foils.

Additionally, extraneous factors, like porosity and chemical composition of the material will also impact its final color appearance.

Factors influencing ink behavior

Finally, it's important to understand how different environmental factors (temperature, humidity, printing environment) can impact color perception.

Color gamut mapping should take all of these into consideration, as red, green, and blue can all be impacted by a variety of environmental factors.

An exploration of different printing methods

There are a few different kinds of printing methods, each of which has a direct impact on color printing and color reproduction. Here's a quick breakdown of some common standard methods of printing, along with some advantages and limitations in terms of color reproduction.

Digital printing

This type of printing uses a digital system and is best suited for customized or personalized products, and limited edition runs where cost and time are critical factors. Benefits include flexibility, speed (minimal set up time means you'll receive your packaging faster), and it's cost-effectiveness.

Limitations include color matching (exact PMS color matching is better with the other two options on this list), and material limitations. Unfortunately, digital printing is difficult with very thick materials.

Rotogravure & flexographic

Ideal for large-scale production runs where quality is the focus. These printing methods are typically used for products that require consistent branding and color accuracy over time and across batches, like the Tiffany Blue and McDonald's Red examples above. In these instances, the specific color must look the same across every type of marketing material or advertisement.

This type of printing also results in ink layers that are thicker and more durable, extreme color consistency across RGB values, and exceptional print quality. The limitations are higher initial costs and less flexibility.

Choosing the right printing method

In addition to light sources, color temperature, and how the RGB model or CMYK model looks when using different printing methods, here are some other things to consider:

Run length

Here, you'll need to think about quantity. If you need a small supply of bags, digital is where it's at. Flexography is good for medium to large-sized runs, and rotogravure for extremely large runs where quality absolutely cannot be compromised.

Cost

Upfront and ongoing costs should be considered. Choosing digital minimized upfront costs, while rotogravure is expensive initially but is more cost-effective at scale. Flexography is the middle ground.

Quality requirements

What level of detail does your packaging need? How consistent does it need to be? While digital is the most cost-effective option, it is also less consistent.

Quality of colors in printing production

Time to market

Do you need your packaging right away or can you afford to wait a bit? Digital printing allows for rapid prototyping, while rotogravure can take awhile to produce.

Solid pigment inks: An exploration

Solid pigment inks are a type of ink characterized by their use of solid particles of pigment suspended in a binder. They are a popular choice for projects where color vibrancy and durability are important (such as in flexible packaging). Learn more about the advantages of using PMS colors with solid pigment inks.

Advantages of using PMS colors with solid pigment inks

When discussing color reproduction, there are some benefits to using PMS colors. First, it's a standardized color palette, so your primary colors will look the same across different batches and printing methods. Second, solid pigment inks are incredibly vibrant and precise.

If your brand has a distinct color vision and requires its colors to look the same across the color gamut, regardless of material, using PMS colors and solid pigment inks can help.

Challenges and things to consider

As with anything, there are some unique challenges and restrictions to keep in mind with PMS colors. First, they can increase the cost of printing especially for small runs. Next, PMS colors are not compatible with all materials.

One additional consideration to keep in mind: some packaging providers offer eco-friendly inks that offer the same benefits of solid pigments while minimizing environmental impact.

CarePac: Pushing the boundaries in flexible packaging

Can embossing and debossing be combined into a single design?

Yes! Debossing, embossing, or any combination of the two can be incorporated into your final print pieces. If you're hoping to save money, though, we recommend choosing one or the other. Since each process uses different settings of die presses, including both techniques into one package can quickly increase the price of your design.

Is embossing and debossing suitable for all types of printing?

No -- ideally, embossing and debossing are reserved for paper and cardstock, and ideally the thicker the material the better. This printing technique should be avoided on thinner materials.

How does embossing and debossing affect printing costs?

Of the two, debossing is the cheaper option because it only requires one plate rather than two. If you want your final print piece to have both embossed and debossed designs, this will be even more expensive than just opting for one. Additionally, if you choose to incorporate foil stamping into your final print piece, this will also impact the price.

CarePac: Pushing the boundaries in flexible packaging

If color reproduction and color management across the material and color gamut sounds complicated, that's because it is. Fortunately, we're the experts and we're ready to help.

Contact us today to discuss how we can leverage our expertise in ink dynamics and color reproduction to take your packaging to the next level. Together, we can create packaging that not only protects your product but exemplifies your brand.

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Full Pouch
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Packaging Design

Embossing vs. Debossing – Textured Printing

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Embossing vs. Debossing:
Unveiling the Art of Textured Printing

Embossing and debossing are each a printing technique, like silk screening, photo etching, or laser engraving. If you're looking to customize packaging or cards with your company logo or text, you've probably come across articles that explain the embossing process and the debossing process during your research. So, which is better? Do embossed graphics look better than those made with debossing techniques?

In this blog, we'll discussing embossing vs debossing so you can choose which tactile effect out of the two techniques is right for you. Regardless of which you choose, the finished print piece will be sure to enhance your brand recognition.

What is the embossing process?

Embossing is when you raise the surface of something, creating a three dimensional effect. The process involves pushing an embossed design up from the material using two metal plates- one metal plate is on the top and the other metal plate is on the bottom.

This technique is ideal for thicker materials, like paper and heavier paper stock, and is often used on wedding invitations and high quality marketing materials. With embossing techniques, the embossed design can be barely raised or very raised -- a very raised design is visually appealing and can be achieved via deep embossing.

A more complex emboss is, of course, often times more expensive to create than a more simple design. If you'd like a combination emboss, multi level embossing, or a repetitive element or recurring pattern embossed throughout a pouch or bag, you can expect to pay a little more than if only one small portion of your card is embossed.

What is debossing?

Unlike embossing, debossing techniques push metal plates into the shape of your design. As such, the design is recessed into the package itself, creating a depressed effect. If you've ever held a luxury bag with the name of the brand imprinted into the bag, this is the depressed effect creating via debossing.

In either scenario, you can choose to leave the debossed area untouched, or it can be "filled in" via ink or foil stamping. One of the key benefits of debossing, especially when compared to embossing, is that the debossing effect doesn't impact the back of the package you're printing. This means you can make the back of the product as visually appealing as the front -- whether that's adding really cool visuals, detailed designs, or some other type of visual embellishment to both the front and the back.

Ultimately, debossing creates more design flexibility, as you can use the same design on the front, the back, or on both sides.

Choosing between the embossing and debossing process

Embossing and debossing both have their own advantages, and which you choose ultimately depends on your personal preference and on what you're hoping to achieve with your packaging.

For example, if you'd like to accentuate raised patterns on your business card or card stock, embossing sounds like it's the right choice for you. However, if you'd like to make a lasting impression by customizing both the front and the back of your luxury packaging, it sounds like debossing is what you're looking for.

Choosing between the embossing and debossing process

Considerations for embossing and debossing

When choosing between embossing and debossing to enhance your brand recognition, there are a few things to consider:

Keep it simple

When in doubt, opt for a design that errs on the side of caution. In this case, the more simple the design, the better. Embossing and debossing help drive attention to a single section of your package -- if the entire thing incorporates debossed or embossed designs, it defeats the purpose.

Use heavier paper stock

The most effective use of embossing and debossing is on heavier paper. Using heavier paper stock for your imprinted or raised design highlights the depth and detail of the finished printed pieces.

Consider the back of your package

Since registered embossing will affect the back of your business card or packaging (i.e., the embossed image will peek through the back), you'll want to avoid embossing if you're hoping to have both the front and back of your package customized.

Both embossing and debossing create finished print pieces that stand out where others fall flat. Although various materials can be used for these techniques, a small pattern or images emboss better into a thicker card stock or paper, like those typically used for a business card. Though we use offset printing and our printer creates beautiful imagery on other materials, the thicker the material, the better.

Embossing vs debossing FAQs

Can embossing and debossing be combined into a single design?

Is embossing and debossing suitable for all types of printing?

No -- ideally, embossing and debossing are reserved for paper and cardstock, and ideally the thicker the material the better. This printing technique should be avoided on thinner materials.

How does embossing and debossing affect printing costs?

CarePac: Your partner in custom printed flexible barrier pouches

Curious about how embossing, debossing, and foil stamping can help take your design to the next level? With nearly two decades of experience in packaging industry, CarePac can help take your custom printed flexible barrier pouches to the next level. Contact us today to get started!

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Art File Setup

What is a Print Ready File? – Guide to Press Ready Artwork

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What is a Print Ready File?
A Guide to Press Ready Artwork

ART SETUP COVER What is a Print Ready File? - Guide to Press Ready Artwork

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What is press ready artwork?

Print Ready (also called press ready) describes any file that is able to meet the specifications required to be setup for final press work and printing.

Download a demo setup file

Click here to download our demo file which illustrates the best practices we outline here.

CarePac's Art Setup Checklist for Designers

If you're preparing artwork for CarePac, either digital printing, flexographic, or rotogravure printing, here is a quick recap of the important points to hit if you want to create print ready artwork:

Outline text: Convert all text to outlines.
Use Vector art: Create all non-photographic text, graphics, and illustrations using vector graphics.
Raster images: Should be at least 300DPI (dots per inch). Link or embed these in the file.
PMS Colors: PMS color are solid pigment colors not a colour mix like CMYK. Refer to Solid Pigment Uncoated Swatch book. PMS colors used with digital printing will not be 100% accurate to the swatch.
Finishes and Effects: Apply a unique off-pallet color to distinguish these areas in the design. Avoid relying on transparency in your design. Also it is best practice to separate designate clear areas in additional panels, see our finish mapping section below.
Bleed: Bleed is not required.
Plate Printing: 10 color stations are available, but we recommend limiting to 8 colours. White ink counts as a color.
Preferred format: Original Adobe Illustrator (AI) or PDF/X-1a.
Canva: For Canva artwork, export both PDF and SVG versions. If possible, share edit access to the Canva project.
Artwork placement: Place all artwork on the same layer as indicated in your dieline. Do not edit the dieline, add color swatches to the color bar, and remove unused color swatches. Avoid placing critical graphics in zipper areas, seal zones, or around hang holes.

Indicating Finishes, Windows, and Metalized Effects

We recommend using a "finish map" which separates these indications from the printed image and the rest of your graphic design. See below for our specific finish mapping recommendations:

Clear areas: Use an obvious color that contrasts with the design to indicate any clear unprinted area.
Finish indication: Use a finish map to indicate type and location of bag's finish.
Metalized effects: Indicate areas of metalized effects using a separate metalized map. Choose a color for the metalized area. Do not use a gradient color, use a solid color like grey.

Note: Use a distinct color to indicate windows in your design.

File Types and Formats

The industry standard, correct file type for flexible printing is Adobe Illustrator. Unlike some printers who may be more selective about the file formats, like most printers CarePac supports Photoshop (.ps), Illustrator (.ai), Adobe InDesign (In), and Acrobat (pdf) but CarePac's design team can also work with Encapsulated PostScript (.eps), Solid Vector Graphics (.svg), or Canva files. Finally, if all you have is a PNG, JPG or ok print images, we have worked with it all and will work with you.

When in doubt, ask. Knowing the correct file format before starting the design can help you avoid time consuming revisions down the line. For example, CarePac's preferred format is an original Adobe Illustrator file or PDF/X-1a, or PDF and SVG for Canva, but another company may prefer something different. "Print ready" varies slightly from printer to printer, so you'll always want to check.

Artwork preparation (size, resolution, bleed area)

Now that you know you're using the appropriate file type, you'll want to make sure the artwork you're submitting is the correct size and resolution. All logos should be within the Safe Design Area (typically 1/8" inside the die line), and that the resolution of the image if it is a raster is at least 300dpi at 100%. Between 300-450dpi is the sweet spot -- anything too large or too small will print poorly on the final printed file. Trust us, if at all possible provide a vector copy of important elements like a logo, to avoid seeing individual pixels on the final image, so just follow the above steps!

CarePac does not require that you bleed the file you submit to CarePac. But if you are going to add a bleed to your own artwork, we recommend adding a 3mm - 5mm (.125" - .25" ).

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.

Type Setting

Text Formatting: Outline all text.
Minimum Font Size: Suggested minimum is around 6 pt. Absolute minimums are 3 pt bold for positive text and 5 pt for reversed text (knockout).
Typesetting Caution: Avoid using Photoshop for typesetting or Smart Objects.

Plate Printing Specifics

Max Colors: Keep under 8 colors (including white ink). Up to 10 colors can be accommodated with additional charges.
Line Screen: 177 line screen based on 300 DPI imagery.
Under 15% Screen: Eliminate from CMYK mix or convert to 100% spot.
PMS Colors: Reference PMS Swatch books. Be aware of differences between on-screen colors and printed or film colors.

Barcodes and QR Codes Specifications

Ideal Size: Between 80% and 120%. Avoid truncating the barcode.
Format: Barcodes should be in Vector line art.
Ink for Barcodes: Use Pantone Black, or 100% Black.
QR Codes: Recommended size is 20mmx20mm. Ensure high contrast (white/black).

Vector vs. raster images

So, what's better: raster images or vector graphics? In our opinion, vector graphics are preferred since this type of artwork can be scaled to any finished size without sacrificing image quality. Vector images don't pixelate and it's native to software like Adobe Illustrator, but it does have its limitations. For example, all photographs will be a rasterized image. Our tip is to reserve raster images just for photographs, and build all logos and other graphics in vector format.

Use the correct colors

To ensure you're creating print ready artwork for graphic designers, you'll need to set your file format to CMYK color mode. If using Pantones or spot ink colors, apply them and make swatches. This way, in color separations, if you preview the colors they'll be assigned correctly. Since all printer files use CMYK color space, your colors will change noticeably if they're submitted in RGB. Since RGB and CMYK are two different color builds that don't correspond to each other, it is absolutely essential that your print ready artwork is submitted using CMYK color model.

It is also important to note that the color modes you see on your screen will be different than the color in "real life". Do not be alarmed- this kind of minor variance is totally normal.

Sending your print ready artwork

There are a few different ways you can send us your print ready marketing materials so we can take your print ready art and turn it into a finished printed product via our proprietary printing process.

Package your artwork and send the entire project in one packaged file
Send any raster image originals that are separate from your artwork.
Convert your text to outlines

We recommend attaching your digital art to the email or uploading the vector file using your printing partner's preferred system, as embedding them within the email will cause your high resolution image to degrade. Remember to send the appropriate file formats, whether that's a vector file or raster image.

Print ready artwork: FAQs

Here are some common questions we get from potential customers about artwork types and their print readiness:

What does print ready artwork mean?

Print ready artwork is a file that's ready to be printed as is. It helps maintain print quality, and should take things like pixel density, bleed area, and the design and print quality listed above in mind.

What are some accepted file types?

CarePac prefers to accept files that are high resolution Illustrator art files (AI, we can also accept Corel Draw and some Canva output but Canva often exports Raster image graphics instead of vectors. Many different file types are accepted by different printers, so it's important to check with your printer.

What if my graphics aren't print ready?

If your graphics aren't print ready or are at an unacceptable quality level, our CareDesign team can work with your graphic designer to get your submission in tip top shape shape for printing. While we prefer to only accept art that match our criteria our team of talented pre-press designers are able to fix a lot, we mean A LOT of problematic art, and have developed processes around most any problem you can imagine. So if you just can't get your new project over the finish line, submit it anyways, we're here to help, that's why we're called CarePac!

What are the requirements for print ready art files?

The criteria for print ready art files are laid out in this post, there maybe adjustments depending on some technical print parameters but following these guidelines will help ensure that the artwork designed by your team can be turned into the perfect print. Some things to keep in mind include using CYMK, using vector paths for anything other than photographs, and avoid placing critical graphics along seams or seals.

I need to make a change to the file's dieline, can I edit it?

No, please don't! Never edit dielines provided to you, if you need a dieline adjustment contact our CareDesign team!

Should I add Crop marks or other indicators of off-canvas cuts, or prints.

While we receive artwork with off canvas information daily, there is no need to include this content in your submission.

Are there any special setup instructions for box bottom bags?

Box Bottom bag setup is generally the same as any other pouch. One key difference to keep in mind is that box bottom bags require two separate print runs – one for the Front, Back, and Bottom, and another for the sides.

Note that alignment between side panel print and front/back may not be 100%.

What are the Line screen specifications by color?

C: 177
M: 177
Y: 177
K: 254
Spot Color: 254
Under 15% Screen: Eliminate from CMYK mix or convert to 100% PMS Spot.

What is the recommended trap size?

Typically the CareDesign team will perform all trapping but a good rule of thumb is 0.3mm. If you want to attempt trapping please see this helpful article and video on our site.

What is the recommended trap size?

Well you smarty pants, yes there is!

Dot: Diamond
Min Dot %: 5%

Get started with CarePac today

Our eagled eyed production team is ready to turn your printable file into the final product you've always dreamed of. With a high quality finish, the appropriate colour mix and pixel density, and state-of-the-art printing plates, our graphic design team promises to create the best print using industry standard practices. Plus, we'll do so using your desired print materials. With our handy checklist, preparing artwork and high resolution images for printing has never been easier. You have multiple jobs: leave the designing and printing to us! Contact us today to get started!

Lets Get Started

Made In
The USA

Full Pouch
Customization

Scalable Printing
Digital & Plate

Packaging Design

Dieline Design Tips & Checklist

Use Our Free Dieline Generator

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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

[ ] 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.

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Flexible Barrier Packaging

Barrier Packaging Guide

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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!

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A Guide on How to Get Your Product in Stores

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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.

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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.

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Packaging Design

Color Gamuts

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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.

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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!

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Prototyping In Packaging Design

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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.

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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 prototypes 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 you're 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 handmade 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. First, 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 prototypes 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. Third, 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 the final product.

We consider these machine-made sizing prototypes to be a mid-ground between low fidelity prototypes such as paper prototypes or handmade 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 an 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 honesty, retailers, distributors and partners can better visualize your product and its 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 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.

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