Among the special touches f we offer to enhance the presentation of your product are:

 

Custom die-cutting

Windowing

Embossing

Foil stamping

Soft touch

Ghost coating

Orange peel

Raised texture

Leather feel

Gloss, Mate and Glitter UV

Patterned and specialized coatings

Special inks

Labeling

Closure systems

Using only the latest in die cutting materials and advanced digital plotting technologies, PM PACKAGING has established a system that allows for even the most complex and unusual folding carton die to be created, all done in-house to ensure flexibility and speed in production.

 

Specialty Substrates and Stock Options

 

Plastics

Foils

Vinyls

Styrene

Screen Printing

HUGE TITLE

add dropb ox etc to site direct files

Although embossing seems to be quite deep visually, it is commonly no more than 15 microns and at most, 25 microns. That’s 25 thousands of an inch. Your average emboss is about 1/64th of an inch. You can see in this photo how the depth of an emboss die affects the appearance of the final piece. Note that as the depth of the die increases, there’s a higher chance of the paper tearing (as can be seen in the “D” of “guide”).

 

While embossing technically refers to a raised surface, embossing can also be done to create a depressed design in a surface. In the graphic design and printing industry, this is usually referred to as “deboss.” For a deboss, the male and female dies are switched so that the topside (front) of the sheet is pressed with the male die and the female die sits underneath it. When a deboss is registered to printing, one can create the appearance of engraving.

 

Dies & Types of Embossing

We mentioned dies above. Dies are the metal plates that have the impression to be embossed engraved or etched out of them. Die can also refer to the male counterpart to the female emboss die, however these are usually referred to as counterdie (for plastic and metal) and make-ready for paper.

Dies are the “master” for any embossing and thus dictate in large part the kind of emboss you will get.

These are the most common types of embossing dies (note that dies are made of metal and that not all metals are created equal—metals most commonly used for emboss dies are magnesium, copper, bronze and steel—covered further below):

Single level die

Single-level die: An embossing or debossing die that changes the surface of the paper at one level. This is both the most common and the cheapest of all embossing dies. The process for creating the die is identical to creating a foil die except that the image is inverted. Single level dies are made usually from magnesium or copper. A magnesium die can be half the price of copper, but caps out at somewhere between 5 and 10 thousand impressions. Moreover, a magnesium die can be destroyed with a single misfeed in the stamping machine. Copper dies are stronger than magnesium and will last for far more impressions.

Multi-level emboss

Multilevel die: A die with a number of distinctive levels. It can be engraved by machine and does not require hand-tooling. Multilevel dies are often made of brass. An example of a multilevel emboss is designs that have a “texture” in the background.

Bevel edge emboss

Bevel-edge die: Similar to a single level die, but with a precise bevel on the image edge, usually between 30 and 60 degrees. The broader the angle, the greater the illusion of depth. Very deep dies must have beveled edges to prevent cutting through the paper.

Chisel (roof) emboss

Chisel die: An embossing or debossing die with a V-shape, using two bevels without a flat bottom surface. It is most frequently used in debossing. It’s also sometimes referred to as a “roof” die.

Textured die

Textured die: An embossing die with an etched texture. Although this might look similar to a sculpted die, it isn’t. It is essentially a single level emboss die with very detailed artwork. These work best for artwork that don’t depend on the detail to look refined. Organic patterns, skin textures and other single level textures can be done with a textured die.

Dome emboss die

Rounded die (domed die): An embossing die that imparts a rounded configuration to an embossed image. It is commonly used for logos and typographical effects.

Sculpted emboss die

Sculptured die: A hand-tooled die, usually made of brass, that embosses many levels through the use of curves, angles, and varying depths. These dies are the most expensive as they require someone to hand sculpt the die based on image references provided (these images usually being transferred to the metal through a photo-etching acid bath for use as a template). They also have the nicest effect, looking like a bas-relief in paper.

Combination foil emboss die (combo die)

Combination die (foil emboss die): More commonly referred to as a “combo die”—this type of die  allows embossing and foil stamping to be accomplished in a single impression. From a design perspective, this means that every part of the design that is being embossed is also being foiled.

Of all these emboss dies, the most important ones to know as a designer are single-level and sculptured (sculpted). Most embossing you see on advertising and marketing products use single-level emboss dies—book covers, brochure covers, business cards, letterhead. The next most common are products that use sculpted dies—higher-end letterhead and business cards, holiday cards and a lot of packaging products. The other dies are far more specialty.

Embossing Applications

While a bunch of the above dies indicate what type of embossing you’ll achieve, there’s actually a whole subset of “types of emboss” and it’s important that as a designer you know what these are:

 

Blind embossed business card

Blind Emboss

Blind embossing does not include the use of ink or foil to highlight the embossed area. The change in the dimensional appearance of the material is the only noticeable difference resulting from the embossing. The blind embossing process provides a clean and distinctive or subtle image on paper stock. It is best used to create a subtle impression or low level of attention to the piece, yet provide some slight form of differentiation for the finished work.

 

Registered emboss

Registered Emboss

Registered embossing is a process that places the embossed image in alignment with another element created with ink, foil, punching, or with a second embossed image.

 

Combination foil emboss die (combo die)

Combination Emboss

Combination embossing is the process of embossing and foil stamping the same image. It involves imprinting and aligning foil over an embossed image to create a foil emboss. A sculptured die, generally made of brass is used for this procedure. The process requires close registration that must be controlled to keep the image and foil matched precisely. The process of embossing and foil stamping is accomplished in one operation with the use of a combination die. The combination die has a cutting edge around the perimeter to cleanly break the excess foil away from the embossed area.

Single-Level Emboss: In this kind of embossing, the image area is raised to just one flat level.

Multi-Level Emboss: In this kind of embossing, the image area is raised to multiple levels having different depths. This gives the embossed image texture and added relief and makes it all the more interesting.

Sculptured Emboss: A sculptured emboss actually refers to a hand tooled process. It is made from a photograph or a drawing with various levels of depth to make the image appear realistic and multi dimensional.

Printed Emboss: In this kind of embossing, the embossed area registers with printed image. Depending on customer requirements and specifications, the bevel can stay inside the printed image or go outside it.

Tint Emboss: This is a relatively new creation where pearl or pastel foil is used for embossing. The methodology is the same as other embossing but the technique is very much in demand and vogue currently. Also, for tint embossing it is best to use white stock because pearl and pastel foils are transparent.

Combo Emboss: This refers to an embossed image that is also foil stamped.

Glazing: This refers to a polished emboss. Glazing is a popular technique used on dark colored stock. The heat and the pressure when pressing the die are increased substantially. This adds shine to the surface. If a very high temperature is used, light color papers can be scorched to change the paper color. This provides for great contrasting designs if done properly.

Debossing: The surface is depressed instead of raised as in embossing.

Thus, there are many types of embossing to choose from depending on the use of embossing.

What is a Mockup or Comp?

You say Mockups – We say Comps…Who are we and what are ‘Mockups’?

Here at Litmus our goal is to produce high quality mockups for you and your business.

This encompasses everything from developing an idea, to finishes, and colour matching. Our aim is to produce perfect products that you are delighted with every step of the way and we understand how important it is to get things right first time.

Physical Mockups are essentially replicas, of an object, machine or structure. These are created to test their uses, and incorporated into experimental processes.

Our packaging specialists have an extensive and reputable track record and the expertise to create your perfect mockup. We are proud to have worked with some excellent clients over time, including the likes of GSK, Unilever and Philips.

Q. WHY WOULD I NEED A MOCKUP?

Many businesses utilise mockups in order to test the usefulness of new products and to aid their development overall. Mockups are also a handy tool for the evaluation of packaging, test marketing and are also used often in advertising campaigns. Mockups can be extremely useful when wanting just the one product, or many, and we have the experience and skill necessary to deliver the goods, meeting your every requirement.
We are proud to say that we can not only deliver completed mockups to you, but we also encourage your involvement every step of the way to ensure that you are completely happy with the finished product. Everything in our business simply starts as an idea, this is particularly useful for those who are looking for a very specific mockup, and can therefore manage the production of your project from the initial stages through to completion, making any necessary changes along the way.

Our mockups also come in a variety of finishes, using different techniques including laminating, hot or cold foiling, spot varnishes, and other special applications. These finishes give a professional look to the finish product, and ensure that all your mockup products have the same consistency in appearance, and quality.

Our team of experts have many years of experience, and have, over time, developed the unique skills, and knowledge necessary for the perfect mockup production process. We are passionate about what we do and through working closely with you, we guarantee that we can produce exactly what you have in mind. In addition, we are extremely up to date with the latest advertising techniques and trends, meaning we are well-informed about what consumers want to see, and how to achieve high quality goals.

Our services are cost-effective and you will be involved in the process from start to finish. Not only does this include product design but also costs and meeting your budget. This ensures that there will never be any nasty hidden costs or surprises along the way.

  • We produce high quality comps printed on the same material as the final product and place great emphasis on exploring beyond the wrealms of what is considered possible.

  • We’re a supplier with our own comprehensive “in-house” resources which helps maintain integrity and confidentiality, it also means you can be confident your project will be delivered upon successfully.

  • Some would say ‘Lightspeed’ if they we’re to describe our ability to react quickly and deliver on a brief. We love a challenge – it is was makes us tick.

  • Scale – sometimes you need one comp but other times several hundred or a few thousand, nothing phases us – whatever you need, consider it done!

  • Looking for something that will help you stand out from the crowd? We can produce comps for trade shows, expo’s or even just for show in your office. Ask about our Giant Mockup service! it is totally EPIC!

What is a Mockup or Comp?

You say Mockups – We say Comps…Who are we and what are ‘Mockups’?

Here at Litmus our goal is to produce high quality mockups for you and your business.

This encompasses everything from developing an idea, to finishes, and colour matching. Our aim is to produce perfect products that you are delighted with every step of the way and we understand how important it is to get things right first time.

Physical Mockups are essentially replicas, of an object, machine or structure. These are created to test their uses, and incorporated into experimental processes.

Our packaging specialists have an extensive and reputable track record and the expertise to create your perfect mockup. We are proud to have worked with some excellent clients over time, including the likes of GSK, Unilever and Philips.

Q. WHY WOULD I NEED A MOCKUP?

Many businesses utilise mockups in order to test the usefulness of new products and to aid their development overall. Mockups are also a handy tool for the evaluation of packaging, test marketing and are also used often in advertising campaigns. Mockups can be extremely useful when wanting just the one product, or many, and we have the experience and skill necessary to deliver the goods, meeting your every requirement.
We are proud to say that we can not only deliver completed mockups to you, but we also encourage your involvement every step of the way to ensure that you are completely happy with the finished product. Everything in our business simply starts as an idea, this is particularly useful for those who are looking for a very specific mockup, and can therefore manage the production of your project from the initial stages through to completion, making any necessary changes along the way.

Our mockups also come in a variety of finishes, using different techniques including laminating, hot or cold foiling, spot varnishes, and other special applications. These finishes give a professional look to the finish product, and ensure that all your mockup products have the same consistency in appearance, and quality.

Our team of experts have many years of experience, and have, over time, developed the unique skills, and knowledge necessary for the perfect mockup production process. We are passionate about what we do and through working closely with you, we guarantee that we can produce exactly what you have in mind. In addition, we are extremely up to date with the latest advertising techniques and trends, meaning we are well-informed about what consumers want to see, and how to achieve high quality goals.

Our services are cost-effective and you will be involved in the process from start to finish. Not only does this include product design but also costs and meeting your budget. This ensures that there will never be any nasty hidden costs or surprises along the way.

  • We produce high quality comps printed on the same material as the final product and place great emphasis on exploring beyond the wrealms of what is considered possible.

  • We’re a supplier with our own comprehensive “in-house” resources which helps maintain integrity and confidentiality, it also means you can be confident your project will be delivered upon successfully.

  • Some would say ‘Lightspeed’ if they we’re to describe our ability to react quickly and deliver on a brief. We love a challenge – it is was makes us tick.

  • Scale – sometimes you need one comp but other times several hundred or a few thousand, nothing phases us – whatever you need, consider it done!

  • Looking for something that will help you stand out from the crowd? We can produce comps for trade shows, expo’s or even just for show in your office. Ask about our Giant Mockup service! it is totally EPIC!

We optimize the packaging processes, aiding with project management, packaging development; internally and in partnership with our production partners.

Structural Design

& Prototyping

 

Pre-press & Printing

 

Converting & Finishing

 

Quality Control

 

Warehousing, Inventory

& Supply Chain

Working in tandum with pre-press and manufacturing, the Logic Design Team delivers a wealth of knowledge and experience that results in the most optimal designs for higher efficiencies and cost savings. Refer to to our Carton Stylesarea to get an idea of a few standard designs to get started with your configuration. Give us a call at (714) 557-2915 and a member from our Design team will be happy to answer any question and assist you with your project.

ur award-winning structural designers are renowned for innovation and are consistently developing cutting edge designs and dynamic structures for paperboard packaging.  Marketers and brand managers look to us to develop something unique, with the understanding that a box is not just a box - it’s a billboard for selling a product and demonstrating product benefits.

Our packaging designers start by evaluating brand objectives and strategies, as well as factoring in retail requirements. We evaluate all other aspects of your packaging needs including the vulnerability factor of products in transit, speed of assembly and packing, stacking strength requirements, presentation and promotion variables, and your budget.  Once all of these parameters are understood, our structural design engineers work to develop economic yet innovative solutions.

white samples, mock ups comps

Design & Prototype for Cartons and Packaging

We have the ability to create a sample of your finished product

Our Packaging Design team combine industry knowledge and the latest technology to give your product the quality packaging it deserves. Combining functionality and aesthetics to produce innovative solutions to all your packaging and corrugated carton needs.

Our services include:

  • Packaging design (including retail packaging, shippers & POS displays)

  • CAD layouts (pdf & eps files)

  • Prototypes

  • Mock-ups (prototypes with artwork)

  • Small run production 

  • Client consultation & technical suppor

.

Overall Value can be defined as the expectation of benefits gained for the price paid.³ Sustained value can be described as the customer’s willingness to specify, utilize, pay for and reorder a given level of quality or service at a given price. Low cost materials and packaging solutions are acceptable for some lower margin product categories but would be unacceptable for others. So, with these considerations in mind, an introduction to the types of paperboard follows including Solid Bleached Sulfate, Coated Recycled Board, Coated Unbleached Kraft and Uncoated Kraft Boxboard.

Solid Bleached Sulfate (SBS) is a prominent packaging material in North America made from mostly hardwood, first generation, chemically pulped fibers that are subsequently bleached, refined and formed in one ply on fourdrinier-type paperboard machines. SBS is white on both sides and throughout the sheet. The relatively short hardwood fibers are coated and polished, creating an impressively smooth print surface that accommodates the highest quality imaging by offset, flexography and gravure. This ultra smooth surface also forms an ideal foundation for film and metallized foil lamination. Most SBS products are coated one-side only (C1S), but some may be partially or fully coated on the back side as well (C2S). SBS generally performs well for embossing, gluing and high-speed filling. It cuts cleanly and has sufficient internal and surface strength properties to accommodate high-speed printing with tacky oil based lithographic inks. SBS is often higher priced as compared with other paperboard substrates.

SBS is not known for tear strength, but generally has good stiffness and compression strength. It may be susceptible to yellowing over time with exposure to white light. It is traditionally the first choice, however, for high quality graphics in personal care packaging, medical, pharmaceutical, confectionery, media and tobacco packaging. The pristine white back side and internal characteristics are preferred by purists for bakery and other such products involving direct food contact.

Primary North American suppliers of SBS include International Paper Company, MeadWestvaco (MWV), Georgia Pacific, Evergreen Packaging, Clearwater, Rock-Tenn and Tembec.

Coated Unbleached Kraft (CUK) is also made from mostly first generation, chemically pulped fibers on fourdrinier-type paperboard machines, however this substrate is formed in two or three layers and is mostly comprised of longer softwood (pine) fibers which contribute to strength. A thin concentration of hardwood fibers are added to the top surface for somewhat enhanced smoothness. CUK is mostly known for durability and resistance to tear. It is white on the top side due to its extremely opaque, titanium-based coating and otherwise brown throughout the sheet. It’s somewhat less expensive than SBS.

CUK is safe for direct food contact and performs well in frozen food applications. It is commonly used for packaging large, club-store multi-pack cereals. A wet-strength version of this grade is used for the packaging of brewery and soft drink bottles and cans, where the paperboard retains 90% of its dry tear strength when exposed to saturated, wet conditions. A general folding carton version of this grade is well suited for frozen foods, snacks and cookies, multi-pack pudding cups, automotive, electronics and sports equipment applications requiring superior tear, tensile and compression strength in a relatively dry environment.

Primary North American suppliers of CUK include Graphic Packaging and MeadWestvaco (MWV).

Coated Recycled Board (CRB), also known as clay coated news, is a dominant material in North America and elsewhere in the world. CRB is generally made from a blend of recycled newsprint, old corrugated containers and mixed secondary paper. Its fibers are often 100% recycled with 35% or more of the content considered “post consumer.” It is comprised of as many as eight or more layers of material with the top ply made of bleached or semi-bleached fibers. A variety of machines are used in its manufacture including fourdrinier, cylinder and hybrid forming systems.

CRB is the most common substrate for low cost folding cartons when recycled content is preferred or required. It is often used for single pouch cereal boxes and other multi-purpose packaging where tear strength and premium print quality aren’t paramount. It is not always used in direct-food applications although food-grade versions of CRB are not uncommon. It often has a one-direction stiffness advantage that can be beneficial for bulge resistance in the packaging of granular products such as rice, pet foods, pancake mix and powdered laundry detergent.

The specification tolerances of CRB are somewhat less stringent than with SBS and other virgin grades. It is often not as strong and tends to carry slightly higher moisture content than other grades. CRB is more absorbent than SBS and CUK, and therefore requires a slightly thicker ink film and/or stronger inks to achieve a given strength of color. As with all other materials, die cutting, creasing and gluing conditions should be adjusted to optimize its performance.

Primary North American suppliers of CRB include Graphic Packaging, Rock-Tenn, Cascades, Paperworks, Strathcona, Caraustar, White Pigeon and The Newark Group.

Uncoated Kraft Boxboard (UKB) is the final grade to be considered in this discussion. Similar to Coated Unbleached Kraft, UKB is comprised of mostly first generation, chemically pulped pine fibers. It is similarly formed on a fourdrinier-type paperboard machine in two layers where the top layer houses a concentration of hardwood fiber for somewhat enhanced smoothness. Since it’s uncoated, however, UKB can be a cost effective alternative to coated paperboard with applications that appreciate an environmentally friendly, natural brown surface. It is lower in density than other grades; therefore, cartons of equal caliper weigh less.

A sturdy material, UKB is safe for direct food contact. It can be reasonably printed by offset, flexo or gravure and performs well in embossing and foil stamping. The quality of graphic reproduction doesn’t match that of coated materials, however, designers are sometimes creative with the earthtone appearance. An interesting technique is to press-apply a white pigmented spot color in certain areas, then build process color on top of that. UKB is a popular choice for institutional food packaging, lawn & garden, hardware, sporting goods and other durable packaging needs.

A primary North American supplier of UKB is Kapstone Charleston Kraft. Rock-Tenn produces an alternative product that is made from 100% recycled old corrugated containers.

Hybrid materials also exist. Some CRB products may have a brown kraft back side, hence the term “Coated Kraft Back” (CKB), or a white layer of fiber on the back side. Mechanically pulped (groundwood) fibers may team up with chemically pulped fibers and varying percentages of recycled fiber content are now seen with some of the grades. Nonetheless, it is incumbent on package designers to understand the effect that these treatments may lend to the performance characteristics of the various grades. In every situation, adjustments must be made in the printing, cutting, creasing, gluing and filling line conditions to optimize performance given a substrate substitution.

Primary North American suppliers of CKB include Graphic Packaging and Rock-Tenn. White-back CRB is produced by Rock-Tenn. Groundwood fibers are employed in some products produced by Tembec. The choice of substrates can be summarized in a decision matrix as follows, understanding that these are guidelines only. Creative license allows for some products to play the field, for example, bar soaps have been successfully packaged in all four materials, and sometimes utilizing the back side of a material as the outward facing side, opens up a new world of possibilities.

DIMENSIONS, LOCKS AND CLOSURES

Dimensions for cartons in the tube and tray styles are expressed as length, width, and depth. Length and width are measured at the open or fill end of the carton. Length is the larger dimension at the open end of the carton. Width is the smaller dimension at the open end and should be given second. Depth is the distance between the open ends of a tube, or from the open end to the bottom of a tray, and should be given third.

At our Taiwan & China printing factories, we are able to lower prices while still providing premium quality packaging Not only will lower costs increase your product competitiveness, but the cost savings will also allow for additional finishing and production process, such as foiling, windowing, specialty coatings & embossing to further enhance the desirability of the packaging, and your product.

In the market for new or re-branded packaging,  we manufacturer unique and durable cardboard items, such as folding carton boxes, litho-laminate boxes, partitions, and inner packaging, carded packaging,  standees, and POS boxes.  Every one of which is created specifically with your industry, product, and bottom line in mind. 

 

We integrate the high-quality printing and converting of your packaging materials with assembly, warehousing, inventory management, distribution and shipping logistics for your supply chain.

Teaming up with Asia Print Packaging allows you to concentrate on what you do best, while we ensure the delivery of your brand at its finest.

Every package provides form, function, and a terrific marketing opportunity!

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