Barrier packaging for food
Table of Contents
What does the process of creating printed packaging look like?
Printed packaging is much more than an attractive film with a brand logo.
It is an element that must protect the product, present it well on the shelf, run properly on packaging machines, and meet quality and technological requirements. That is why the packaging production process requires cooperation between several areas: sales, technology, graphic design, production, quality control, and logistics.
Well-designed packaging should be adapted not only to the product, but also to the packaging method, storage conditions, expected shelf life, and sales channel. Below, we explain step by step what the process of creating printed packaging looks like.
Consultation and defining the customer’s needs
The first stage is a conversation with the customer. At this point, we need to understand what the packaging will be used for and what requirements it should meet.
Important factors include, among others: the type of product, its weight, form, fat or moisture content, required shelf life, packaging method, type of packaging machine, transport conditions, and expected visual effect.
Different parameters will be required for packaging loose products, and different ones for sweets, bread, vegetables, frozen foods, meat, or products requiring a high barrier. Already at this stage, it is worth determining whether the packaging should be transparent, white, matt, metallised, pearl, barrier, mono-material, or intended for recycling.
The more precise the information provided at the beginning, the easier it is to choose the right material and avoid problems at later stages of production.
Selection of the right material
After collecting information about the product and the packaging method, the next step is selecting the material structure. This is one of the most important stages of the entire process, because the material determines whether the packaging will work properly on the packaging line and whether it will protect the product effectively.
Depending on the application, materials such as BOPP, CPP, PE, PET films, metallised films, multilayer laminates, barrier films, or mono-material solutions can be used.
Material selection takes into account parameters such as sealability, mechanical resistance, oxygen, moisture or aroma barrier, stiffness, slip, surface appearance, lamination possibilities, and compliance with the customer’s requirements.
In practice, this means that packaging should not be chosen only on the basis of price or appearance. Even a visually attractive film will not fulfil its function if it does not seal well on the machine or does not provide the product with proper protection.
Preparation of the graphic design
The next stage is preparing the graphic design for printing. The design must be not only aesthetic, but also technically correct. Bleeds, safety margins, text placement, barcodes, markings, photocell marks, and elements required by regulations are all important.
At this stage, the colours, number of colours, compliance with the brand’s visual identity, and the possibility of reproducing the design in the selected printing technology are also checked.
In the case of film packaging, the design should be prepared with the later packaging process in mind. Some graphic elements cannot be placed too close to the seal, cutting line, or folding areas of the film. That is why cooperation between the graphic designer and the packaging manufacturer is very important.
Preparation of printing plates
After the graphic design has been approved, printing plates are prepared. These are the elements that make it possible to transfer the print onto the film.
This stage requires precision because the quality of the prepared plates affects the later print quality. Well-made plates make it possible to achieve a repeatable result, sharp details, readable text, and colour consistency with the approved reference.
Printing plates are especially important in repeat production. If the customer regularly orders the same packaging, once-prepared plates allow subsequent orders to be completed efficiently.
Printing on film
The actual printing process then begins. In the case of flexible packaging, flexographic printing is most commonly used, as it works well for producing film packaging in rolls.
During printing, ink is applied to the surface of the material according to the prepared design. Colours, registration, print quality, readability of markings, and compliance with the approved reference are all checked.
At this stage, process stability is very important. Packaging produced in larger volumes must maintain repeatable quality from the beginning to the end of the order. Colour differences, print shifts, or registration errors may later affect both the appearance of the product and how the packaging performs on the packaging machine.
Quality control
Quality control is one of the most important elements of packaging production. Both visual and technical parameters are checked.
This includes, among others, print quality, colour consistency, registration, material thickness, lamination quality, roll width, cutting accuracy, sealability, and compliance with technical arrangements.
In the case of packaging for the food industry, repeatability is particularly important. The customer must be sure that the material will work on their packaging machines and will not cause downtime, excessive waste, or complaints.
Good quality control reduces the risk of production problems on the customer’s side. That is why packaging should be treated not only as a print carrier, but as an element of the entire production process.
Packaging, storage, and delivery
After successful quality control, the finished rolls are packed, secured, and prepared for shipment. Depending on the arrangements, it is also possible to store materials or finished products for future orders.
For many manufacturing companies, this is very important because it allows them to plan deliveries more effectively and secure production continuity. Especially during periods of increased demand, such as the fourth quarter, timely delivery and packaging availability are crucial.
Why is it worth planning packaging production properly?
The process of creating printed packaging requires time, accuracy, and proper preparation. Mistakes made at the beginning can lead to problems at later stages: delays, colour inconsistencies, sealing problems, increased waste, or downtime on the packaging line.
That is why it is worth starting cooperation with a packaging manufacturer as early as possible, especially when the product is new, requires testing, or has unusual requirements. A well-prepared process helps reduce risk and move from the idea to the finished packaging in an organised way.
Summary
The creation of printed packaging is a process that involves much more than printing itself. It starts with analysing the needs of the product and ends with the delivery of finished rolls prepared for work on the packaging line.
The key stages are consultation, material selection, design preparation, plate production, printing, lamination, slitting, quality control, and delivery. Each of them affects the final result: the appearance of the packaging, product safety, packaging efficiency, and the customer’s comfort of work.
Well-designed printed packaging should combine aesthetics, functionality, and reliability.
Looking for printed packaging for your product?
Contact us. We will help you choose the right material, prepare the design for production, and plan the process so that the finished packaging meets the requirements of your product and packaging line.
FAQ
The production of printed packaging begins with a consultation and collecting information about the product. Important details include the type of product being packed, packaging dimensions, type of packaging machine, barrier requirements, expected visual effect, planned production volume, and delivery deadline.
To prepare a quotation, it is worth providing the product type, the width and length of the packaging or film, material structure, number of print colours, production volume, winding type, seal requirements, barrier requirements, and the intended use of the packaging. If you already have current packaging, it is worth sending a sample or specification.
Printing plates are printing forms used to transfer graphics onto film. The precision of the print, sharpness of details, readability of text, and production repeatability depend on the quality of their preparation.
Yes. Samples help check whether the selected material will be suitable for the product and whether it will work properly on the packaging machine. Testing is especially important for new projects, changes in packaging structure, switching to a mono-material, or implementing a new supplier.
During quality control, several elements are checked, including print compliance with the design, colours, colour registration, roll width, cutting quality, material thickness, lamination quality, sealability, and overall compliance of the product with the agreed specification.
