There are only a few common issues with files: using raw screenshots as assets, submitting RGB files, forgetting to convert text to outlines, insufficient bleed, and low image resolution. None of these are hard to avoid, yet any one of them can compromise the quality of the final product. Checking for these items before sending files to the manufacturer can save a lot of trouble later on.
When it comes to the back-and-forth of packaging prototyping, half of the rework actually stems from issues with the design files. If a file is missing bleed, uses the wrong color mode, or places the die-cut line on the wrong layer, the manufacturer cannot proceed immediately. Understanding file specifications can drastically reduce communication overhead and ensure the prototype is right the first time.
The die-cut layout defines the boundary between structure and content. Die-cut lines and crease lines should be placed on separate layers—distinct from the design content—with dimensions clearly marked. Text and graphics need a safety margin from the cut line (usually at least 3mm) to avoid being accidentally trimmed off. Special structural features, window cutouts, and fold directions must also be clearly indicated in the file.
File format and resolution also impact the outcome. Vector files (AI, CDR, PDF) are the preferred choice, as they keep graphics and text crisp and clear. Raster images should have a resolution of at least 300 dpi to prevent pixelation when enlarged. Remember to convert fonts to outlines; otherwise, the layout may break if the manufacturer’s computer lacks the specific font. Finally, submitting a single PDF makes both verification and production easier.
Bleed is a fundamental requirement for print files. Since cutting involves slight tolerances, background colors and images must extend beyond the trim line—usually by about 3mm—to prevent unsightly white edges after cutting. Skipping this step often results in white lines along the box edges; while rework is a hassle, missing a delivery deadline is a serious problem.
If you are unsure about a design file, consult the manufacturer first. Reliable packaging manufacturers offer design support; sending them a draft for review allows them to clarify print requirements and necessary adjustments in one go. We also provide file checks and modification suggestions—feel free to send us your draft.
Color modes must adhere to printing standards. Since printing uses the CMYK four-color process, design files should also be set to CMYK mode; while RGB colors look vibrant on screen, they often appear dull or dark when printed. For brand-specific spot colors, specify the Pantone code so the printer can mix the ink accordingly. Also, keep in mind that there is an inherent difference between on-screen colors and the final printed product; the physical proof serves as the definitive reference.
