Packaging issues rarely appear as a single dramatic failure. They accumulate: a batch arrives slightly outside the approved colour tolerance, a stack of mailers loses stiffness under pallet load, a shipment clears customs only after several rounds of document requests.
Each of those is preventable. This page describes the processes we use and the evidence we can provide.
Colour consistency management
Why colour drifts between runs
Offset printing transfers ink through a chain: plate to blanket cylinder to substrate. Each transfer introduces a small deviation. The cumulative result depends on temperature, humidity, board stock and its moisture content, ink batch, press condition and makeready quality.
None of these variables is identical between a run in March and a run in November. Without a formal colour management system, each becomes an uncontrolled contributor to variation.
Digital printing avoids the plate transfer but has its own consistency characteristics governed by ink deposition and substrate coating. For most long runs, offset combined with G7 calibration produces tighter batch-to-batch agreement.
Temperature
Press and substrate temperature shift between seasons and between production runs.
Humidity
Affects board moisture content, which changes dimensional stability and ink lay-down.
Ink batch
Ink properties vary slightly between production batches of the same formula.
Press condition
Rollers, bearings and impression settings change with wear and require periodic adjustment.
What G7 specifies
G7 is a colour specification and calibration method developed for offset printing. Its purpose is to define a narrower, more reproducible operating condition than legacy methods allow.
Under G7, the acceptable deviation from target is measurably smaller than under older standards. For a brand ordering the same structure repeatedly over two years, this determines whether the product line reads as coherent or gradually fragments.
If a brand ships 2,000 ivory boxes and later reorders 5,000 more, a visible shift between the two deliveries makes them look like different product lines — even where the specification has not changed.
How we apply it
- 1
Prepress
Artwork preflighted and profiled against your reference standard. Resolution, total ink coverage, trapping and overprint settings are checked before plates are prepared.
- 2
Calibration
The press is set to G7 targets using densitometry before each run begins, rather than assuming previous settings still hold.
- 3
In-process control
Colourimetric readings taken during the run, not only at makeready. Readings beyond tolerance trigger a press stop.
- 4
Reference retention
Your approved sample is retained and logged against the production batch for future reorders.
What to ask any supplier
- Do you calibrate before each run, or only when someone raises it?
- Do you take readings during the run, or only at makeready?
- Do you retain the approved sample for future reference?
- Can you show the batch record linking finished goods to ink lot and press settings?
- What tolerance do you commit to, in measurable units?
A supplier answering these precisely operates a colour management system. One answering with adjectives is not.
Four-stage quality inspection
- 1
Incoming material
Board weight, thickness, moisture content and colour measured against the approved specification before any press runs. Material failing this check is rejected before production.
- 2
Prepress
Artwork checked for resolution, bleed, trapping and colour profile. Dielines validated against the actual tooling rather than the original design file.
- 3
In-process
Colourimetric readings during the run, dimensional checks on cut and creased parts, registration verification at each printing signature.
- 4
Final inspection
Finished dimensions measured against tolerance, print fidelity assessed against the approved sample, surface finish checked for defects, drop or compression testing where the product requires it.
What we check on a finished box
| Check | Method |
|---|---|
| Dimensions | Calibrated measurement against specification |
| Print colour | Spectrophotometer reading against approved sample |
| Registration | Visual and instrumented check at each signature |
| Surface finish | Inspection under standardised lighting |
| Structural integrity | Drop or compression test where specified |
| Print adhesion | Tape test on laminated surfaces |
| Barcode legibility | Scanner verification where barcodes are printed |
Not every project requires every check. We agree the inspection plan with you at quotation stage based on what the product is and how it will be handled.
Certifications
We maintain the following certifications. Copies are available on request.
| Certification | Scope | Relevance to your order |
|---|---|---|
| FSC | Forest Stewardship Council chain of custody | Fibre content traceable to certified sources |
| ISO 9001 | Quality management system | Documented controls from enquiry to final inspection |
| ISO 14001 | Environmental management | Waste reduction, water-based inks, solvent recovery |
| ISO 45001 | Occupational health and safety | Audited working systems on site |
| RoHS | Restriction of hazardous substances | Conformance for electrical and electronic packaging |
| GPSR | EU General Product Safety Regulation (EU) 2023/988 | Documentation package for EU market placement |
Where an order is placed against a specific certification requirement, we confirm the certificate number applying to that production run.
EU compliance: GPSR
Since 13 December 2024, Regulation (EU) 2023/988 applies to products made available on the European market. It requires an economic operator established within the EU, product traceability, and technical documentation including manufacturer identification, material composition and safety information.
Packaging falls within scope because it may contact food, come into contact with children, or present suffocation or sharp-edge hazards.
Common gaps we encounter
No EU responsible party identified
Packaging states only a non-EU manufacturer and a forwarding agent’s contact, which does not satisfy the requirement for an economic operator established in the EU.
Material declarations incomplete
A board certificate may be provided while ink, adhesive and coating are unassessed. All components require coverage, not only the substrate.
No batch linkage
A complaint arrives and there is no record linking affected units to a production run, preventing investigation.
Documentation not aligned to shipment
Documents prepared for a previous order are submitted for a different one, or in a format your customs broker cannot use.
Documentation we provide for EU-bound orders
- Material composition declaration Covering board, ink, adhesive and finishing.
- FSC certificate number Where FSC material is specified for the order.
- RoHS conformance statement Where applicable to the product type.
- Batch traceability records Linking the shipment to its production run.
- Manufacturing identification Facility details and production site information.
- Declaration of conformity Where your compliance process requires it.
Documentation we cannot provide
Your own economic operator obligations under GPSR. The regulation requires an entity established within the EU to be responsible for the product placed on that market.
Our documentation supports your compliance obligations. It does not discharge them. If you do not currently have an EU responsible party in place, that is a matter to resolve on your side and is not something a packaging supplier can provide on your behalf.
Sampling and approval
Bulk production begins after you have approved a physical sample. The sample is checked for structure, dimensions, materials and finish — not appearance alone, since a box can look correct and still be dimensionally wrong.
Where the schedule allows, we produce and send the actual production unit. Otherwise we provide photographs and video of the run.
Retain your approved sample. Future orders are calibrated against it, and it is the reference if a question arises about a later delivery.
Third-party inspection
Third-party pre-shipment inspection is accepted on any order. Our facility access is open to SGS, BV, TÜV and other inspection agencies, and we do not restrict inspection scope or timing.
You are not required to rely solely on our own inspection report.
Traceability and records
Each production order carries a batch record linking finished goods to the board certificate, ink batch, press run and inspection readings.
If a claim arises six months after delivery, we can reconstruct what was used and what was measured. This is why we ask you to inform us of your order reference when raising a query — it allows us to locate the relevant records without guesswork.
Records are retained for the period required by our quality management system. Longer-term retention can be arranged for repeat customers where project timelines extend beyond the standard period.
How to raise a quality issue
- 1
Document the issue
Photograph what you have received, including carton markings if visible.
- 2
Quote your reference
Give us the order reference or your delivery date so we can locate the batch record.
- 3
State the quantity
Tell us how many units are affected so we can scope the investigation.
We investigate against the batch record and respond with findings. Where we produced the defect, we correct it — whether that means replacement, rework or a commercial resolution. Where the issue relates to handling after delivery, we explain what the evidence shows.
Frequently asked questions
What information do I need for an accurate quotation?
Structure and intended use; product dimensions as length × width × height or diameter × height; materials and surface finishing, or ask us to recommend; printing colours as CMYK or Pantone; quantity; and the delivery destination for a complete delivered-cost quotation.
Can you assist with design?
We have designers and engineers who can produce structural drawings and artwork. This is provided at no cost with a quotation request. If you already have design files, send them and we will check them for production feasibility before quoting.
Can we get samples, and is there a charge?
Stock samples require only the delivery cost. Custom samples may carry a setup charge, which is commonly credited against a production order. We quote sample cost before producing it.
What is the difference between CMYK and Pantone?
CMYK uses four process inks — cyan, magenta, yellow and black — in overlapping halftone screens to produce continuous tone and photographic images. Pantone (PMS) is a system of standardised inks with defined formulas, used where a specific colour value must be reproduced consistently across production runs.
What tolerance can you commit to on colour?
We calibrate to G7 targets and measure against your approved sample. We do not quote a numeric tolerance figure without knowing your specific colour, substrate and structure, because achievable tolerance depends on those three variables. We will state the tolerance we can hold once we have that information.
How do you handle quality problems?
Each order carries a batch record linking finished goods to materials, ink batch, press run and inspection readings. We investigate against those records and respond with findings. Where the defect originates from our production, we correct it.
Will you ship to our country?
We ship to Europe, North America, Australia and other markets. We coordinate FCL, LCL and air freight and can provide documentation your customs broker requires. Incoterms affect cost and responsibility split, so we agree the term before shipment.
What are your minimum order quantities?
They depend on structure and size. Folding cartons accept lower quantities because no tooling is required. Rigid boxes and custom shapes carry higher minimums because of dieline tooling and makeready. We confirm the MOQ when quoting.
How long does production take?
Standard production windows are 7 days for express digital runs, 15 days for standard offset production and 30 days for bulk or complex orders. We confirm a specific date in the quotation, which is the date we work to.