Having a finished logo file is not the same as being ready to place a packaging order. Before artwork can go to print, you need to confirm the packaging structure, dimensions, material, and finishes, then apply your design to a dieline built for those specifications.
PackMojo supports brands ordering everything from mailer boxes to rigid gift boxes. In our experience, orders tend to move faster when the packaging specifications and artwork are prepared correctly before production begins. This guide walks through the process from dieline to delivery, including where delays commonly occur.
1. Confirm the Structure, Material, and Finish
Before creating a dieline, confirm the basic specifications of your packaging. These decisions determine its structure, how the artwork should be prepared, and what will appear on the final quote.
- Box style: Choose a structure based on the product, distribution method, and intended customer experience. A corrugated mailer box can be used for direct-to-door eCommerce shipping, while a folding carton suits lightweight retail products. Rigid boxes are commonly used when presentation is a priority.
- Dimensions: Measure the product and account for any inserts, dividers, accessories, or protective space required inside the box. Even a small dimensional change will require a different dieline.
- Material: Material affects durability, weight, appearance, and freight volume. Corrugated board provides protection for shipping, paperboard is commonly used for folding cartons, and the chipboard in rigid boxes creates a denser structure.
- Finish: Confirm whether the design will use options such as matte or gloss lamination, foil stamping, embossing, or spot UV. These finishes may require separate artwork layers or additional production setup.
These specifications should be finalized before artwork begins. Changing the structure, dimensions, or material later may require a new dieline, while changing the finishes can require artwork and quote revisions.
If you are also comparing how these choices affect unit pricing, PackMojo's guide to custom packaging costs explains how material, finishing, and order volume interact.
2. Get the Correct Dieline
A dieline is a flat, two-dimensional template showing where a package will be cut, folded, scored, and glued. Think of it as the pattern a tailor uses before cutting fabric. It identifies each panel, tab, glue flap, fold line, and cut line so the artwork appears in the correct place after assembly.
Once your box style, dimensions, and material specifications are confirmed, PackMojo provides a dieline tailored to that configuration. Your artwork should be created directly on this template.
Designing first and trying to fit completed artwork onto a dieline later often creates avoidable problems. A logo may cross a fold, text can sit too close to a cut line, or a graphic intended for one panel may wrap around a corner.
Keep these points in mind:
- Confirm the packaging specifications first. The structure, dimensions, and material need to be settled before the final dieline is created.
- Use the exact dieline supplied for the order. A change in dimensions or structure means the existing template may no longer be suitable.
- Build the design directly on the dieline. Do not resize or alter the dieline to accommodate finished artwork.
- Keep dieline guides separate from the artwork. Cut, fold, bleed, and safe-zone markings should remain on their designated layers.
PackMojo accepts print-ready artwork in AI, PDF, or EPS vector formats. More details are available in our packaging dieline design guide.
3. Prepare Print-Ready Artwork
Print-ready artwork is built to the specifications required for production. A file that looks correct on a screen may still need adjustments before it can be printed accurately.
Use the Right File Format
Logos, text, and line artwork should generally remain in vector format because vectors can be resized without losing sharpness. Photos and textures can be raster images, but they should be embedded in the file and have sufficient resolution at their final printed size.
PackMojo accepts AI, PDF, and EPS vector formats. When preparing the file:
- Outline fonts to prevent typeface substitutions
- Embed linked photos and graphics
- Keep important artwork on clearly named layers
- Remove hidden or unused design elements
- Avoid flattening elements that may need prepress adjustments
Raster images should generally be at least 300 PPI at their final print size. Increasing the resolution after enlarging a small image will not restore missing detail.
Set Up Colors for Print
Artwork should use CMYK or approved Pantone colors rather than RGB. RGB is designed for screens, while CMYK is used for most printed packaging. Colors can therefore look different when artwork is converted from RGB to CMYK.
CMYK is suitable for many packaging designs. If a brand color requires tighter matching than standard CMYK can provide, specify an appropriate Pantone color. Pantone printing may affect production costs, so it should be confirmed as part of the packaging specifications.
The material and finish also influence color. The same ink can appear different on white paperboard, uncoated kraft stock, or a laminated surface. A physical proof is more reliable than a screen when color accuracy is important.
Add Bleed and Respect the Safe Zone
Bleed is the extra artwork that extends beyond a cut line. It allows for small cutting tolerances and helps prevent unprinted edges from appearing after trimming.
The safe zone is the area inside a cut or fold line where important content should remain. Logos, text, barcodes, and other critical elements placed too close to an edge may be trimmed, folded, or distorted.
Always follow the bleed and safe-zone measurements shown on the supplied dieline rather than applying a general value. Requirements can vary by packaging type and production method.
4. Review Proofs and Samples
Proofs and samples help identify problems before a full production run begins. The right option depends on whether you need to test structure, artwork, color, finishes, or the complete package.
Structural Sample
A structural sample is a blank, unprinted version of the packaging. It is used to confirm the dimensions and physical structure.
Use it to check questions such as:
- Does the product fit without excessive movement?
- Does the lid or closure work correctly?
- Does an insert hold the product securely?
- Is the package practical to assemble and pack?
Structural samples are especially useful for products with unusual shapes or custom inserts.
Print Proof
A print proof is a flat, two-dimensional CMYK printout produced digitally on proofing paper. It provides a close preview of colors and helps identify artwork or alignment issues, but it is not printed on the final packaging material using the production press.
Press Proof
A press proof is a flat printout produced with the actual printing facilities and material intended for production. It can use CMYK, Pantone, or both and is suitable for evaluating final print colors, finishes, and add-ons such as foil stamping or spot UV.
Pre-Production Sample
A pre-production sample is produced using the intended production setup and shows the complete package at production quality. It is the most suitable option when you need to evaluate the assembled structure, print, material, finishes, and add-ons together.
PackMojo also offers a sample kit for comparing packaging structures, materials, and finishes before choosing a specific configuration. The kit starts at US$29 with shipping included, and its cost is reimbursed when you place your first production order.
Sampling adds time before production, but it can reduce the risk of discovering structural, artwork, or color issues after the full quantity has been manufactured.
5. Approve the Order for Production
Once the artwork has passed prepress review and the required proofs or samples have been approved, the order can move into production.
PackMojo's standard production time is typically 12 to 16 days. This covers steps such as printing, finishing, cutting, assembly, and quality control. Shipping time is additional.
Larger production runs or more complex packaging may take longer. High-volume orders and specialty structures can take approximately three to four weeks, depending on the specifications. Examples include multi-piece rigid boxes, magnetic closures, custom foam inserts, and designs combining several finishing processes.
Build additional time into the schedule when the project involves:
- A complex or custom structure
- Multiple finishes or add-ons
- High order volumes
- FSC artwork approval
- Peak production periods
- More than one sampling or artwork revision round
FSC-certified materials are available for eligible corrugated and cardstock packaging. If the FSC™ label will appear on the artwork, the design must follow FSC requirements and be approved before production. This process can add approximately 5 to 10 days.
6. Plan Shipping and Delivery
The selected freight method can affect the total timeline as much as production. Air freight is faster but usually costs more, while ocean freight generally offers a lower cost per unit for larger shipments.
PackMojo's typical shipping estimates are:
- Air freight: Approximately 1 to 3 weeks
- Ocean freight: Approximately 4 to 7 weeks and available for shipments over 100 kg
Split shipments are also supported. For example, a brand can send part of an order by air for an upcoming launch and ship the remaining quantity by ocean to reduce the overall freight cost.
Packaging structure also affects shipping and storage volume. Folding cartons and mailer boxes generally ship flat and require assembly before use. Traditional rigid boxes usually arrive assembled, so they occupy more space in transit and at the warehouse.
Collapsible magnetic rigid boxes are an exception. They ship flat and use built-in adhesive sections for assembly, which can reduce freight and storage volume compared with non-collapsible rigid boxes.
Exact freight requirements depend on the packaging dimensions, quantity, carton pack-out, and delivery location. When planning a launch, work backward from the required delivery date:
- Add the estimated freight transit time.
- Add the expected production time.
- Include time for artwork review and approval.
- Include any proofing or sampling rounds.
- Add a reasonable buffer for revisions or transit delays.
This approach gives the packaging team, fulfillment partner, and launch team a more realistic schedule.
Closing Thoughts
A custom packaging order begins before the artwork is placed on a box. Start by confirming the structure, dimensions, material, and finishes. From there, use the correct dieline, prepare print-ready artwork, and select the proof or sample that answers the questions most important to your project.
PackMojo offers mailer boxes and folding cartons from 100 units, while rigid boxes and most other formats start from 300 units. When you are ready to begin, you can configure your packaging, receive a quote, and order samples through the PackMojo platform.