Much more happens before a box is finished
When we hold a finished package in our hands, we rarely think about how many different production steps were needed to turn a flat sheet of paper or paperboard into a functional box. Yet the production of a custom paper box begins long before the printing press.
First, the product needs to be understood
How large is the product? How heavy is it? How will it be placed into the box? Will the packaging primarily be used for transport, or will it be displayed on a retail shelf? Does it need an internal insert? How should the box open?
With custom packaging, these questions need to be answered before production begins.
Once the requirements have been discussed, the structural design and die-cutting layout can be developed. At Sz.Variáns, after the structural design stage, we can also create a prototype – if necessary in several versions – so the functionality of the box can be tested before serial production.
After the structure comes the graphics
Once the box construction has been finalised, the graphic artwork can be prepared.
At this stage, millimetres, bleed areas, colours and technical markings all matter. The graphic design must not only look good on screen: it also needs to fit the final die-cutting layout precisely and be suitable for the selected production technology.
Printing, finishing and die-cutting
This is where the more visible part of the production process begins.
The artwork is printed and, depending on the type of packaging, various finishing techniques may then be applied. Die-cutting gives the printed sheets their final box shape, followed by folding, gluing or other converting operations.
Special constructions may require significantly more manual work. In the case of rigid boxes, for example, bookbinding greyboard forms the stable structure of the box, which can then be wrapped or laminated with different types of paper.
The goal is always the same
Whether it is a simple folding carton, a paper bag or a special rigid gift box, the objective is to create packaging that not only looks good but is also manufacturable, functional and suitable for the product.
That is why, at Sz.Variáns, packaging production is not a single operation but a series of interconnected design and manufacturing processes.
