Custom Packaging Explained: What Is Tooling?
In custom packaging, we call print plates and cutting dies “tooling.” These are used to print your unique graphics and cut out your custom box from a corrugated sheet. Print plates and cutting dies are highly specialized manufacturing tools that are custom made on your first order.
For orders over 500 pieces, or any flexo printed order, there will be an additional one-time charge for tooling to cover materials and labor for your custom print plates and/or cutting dies. Your tooling will be made specifically for your box. Although your cutting dies and print plates will live at the manufacturing plant they are owned by you and, if maintained well, should last for tens of thousands of impressions!
Print plate and cutting die with finished box
Print Plates
Print plates are usually made from a rubber-like photopolymer material. Your design is “built” using a laser - not unlike a rubber hand stamp. In fact, the process used in flexo printing, is similar to using a hand stamp in a few ways.
The ink is applied to the print plate then stamped on to the uncut corrugated sheet. If your design has more than one color, this process will need to be repeated for each color. That means you’ll need to purchase a separate print plate for each color in your artwork.
Print plates cannot be adjusted. If you need to make any changes to the art built on to your print plate, even just your website URL, UPC codes, or your copy, you’ll need to purchase a whole new print plate (and sometimes the entire set used on a box). However, you can make changes to the ink color whenever you like without changing the plate(s)!
Digital print is a plateless process. If you’re looking to get your startup costs down, or if you anticipate a change in your branding, digital print could be a great option.
Flexographic print plate for corrugated boxes
Cutting Dies
Cutting dies can be curved or flat depending on the diecutter. To create a cutting die, a bendable steel knife or score called a “rule” is shaped by hand and placed into the die board. A collection of other facets made from foam, rubber, or wood are all attached to the die board as well to allow for the correct amount of pressure needed to cut through the corrugated sheets while allowing scrap material to be properly ejected, collected, and recycled.
Cutting die rule is made to cut through, perforate, score, or crease the corrugated sheets, so your boxes can be assembled with ease and perform the functions they were designed for.
Rotary cutting die for corrugated boxes
Similar to print plates, cutting dies cannot be adjusted. If you need to make any changes to the structure of your box, you’ll need to purchase a new cutting die.
If you’re printing different art versions on the same structure, you can use one cutting die! For example, many beverage brands will use the same size box for different flavors. In this case you can use varied print plates and the same cutting die for each.
If you’re printing on full print coverage RSC, you may not need to purchase a cutting die. With compatible artwork, this style box can run on a specialized press called a Flexo Folder Gluer (FFG). FFGs can cut nearly any size RSC without a cutting die.
Good to Know…
Digital Print orders do not require print plates
Digital print orders under 500 pieces are CAD cut and will not require a cutting die
Flexo print requires one print plate per color (per structure)
Cutting dies and print plates are built for your box and in most cases are owned by you
