Four Things You Probably Did Not Know About Custom Printed Corrugated Mailer Boxes

Context Media 11x12x2 mailer boxWe freely share the information we have gathered along the way and here are a few things that usually get a quick “I didn’t know that” from our customers and friends.

  • The Long Dimension is Not Always Across the Front

In most designs that you see out there, the box length is from the front (left corner to the front right corner) and it happens to be the longest dimension of the three (L x W x H) . Mailers are made that way primarily for ease of opening and removal of the product being shipped.

However, in some applications like the one shown in the photo, the product will present better if the longer dimension is front to back so that something like a title or photo is positioned correctly. Today it is all about enhancing the customer’s experience and little things like proper product orientation do make a difference.   Corrugated Board Flutes

  • “Thinner” board Combinations such as E-flute do not weigh less

As most people search for ways to reduce shipping weight, usually due to DIM (dimensional) weight, they are often led to believe that a thinner board like E-flute is going to weigh less than a thicker board combination such as B-flute.

For example, B flute corrugated board has flutes that are 1/8” high and there are typically 50 flutes per inch. E-flute board is one half the thickness at 1/16” but usually has around 94 flutes per foot. In other words, they both contain about the same amount of paper (board) so the weight is almost identical.

There are many reasons to use E-flute board but most are cosmetic because E-flute simply has a more retail, less industrial look. It is not a good choice however if the goal is overall weight reduction.   image001

  • Standard Corrugated Colors Were NOT Developed by the Corrugated Industry

The standard “GCMI” colors used by the corrugated industry were actually developed by the Glass Containers Manufacturing Institute. Why is that so? No one has been able to give me a definitive answer but the assumption is that the glass industry was one of the first to use a lot of corrugated containers for bottles and jars. When printing was required, it was easier to utilize the colors that the GCMI had already approved.

Today using those “standard” GCMI colors save time and money. They also provide color consistency that might otherwise be problematic, especially on shorter runs.

  • Print Plate Pricing is Determined By the Size of the Box

That is kind of true to some degree, but there are really three factors that determine the price of a flexographic press print plate. They are:

  1. The overall size of the layout of the box. For example, a box with a two out layout will require a smaller plate than the same box in a four out configuration.
  2. The overall size of the print area. It may be a large box with a small print area or a much smaller box with a much larger print area.
  3. The complexity of the graphic design. Things like flood coats, aka full bleeds, screens and detail may impact the type of plate required, and thereby the price.

The good news is that most print plates today will last for a million impressions or more. For most customers, unless you change the copy or the size of the copy being printed, you should never have to replace your plates due to wear.

We believe that every question deserves an answer and we are always happy to help customers understand the process in an effort to maximize the positive results and minimize the cost of their branded packaging.

Contact us at Salazar Packaging or call us at 630-551-1700 for a confidential, no cost, and no obligation discussion of your needs.

Related posts:

http://blog.salazarpackaging.com/sustainable-packaging/cost-estimates-for-custom-printed-e-commerce-and-subscription-boxes/

https://greenpackaginggroup.com/industry-experts/shipping-boxes-that-wow-with-bright-flood-coat-printing/

http://blog.salazarpackaging.com/sustainable-packaging/e-commerce-boxes-that-sparkle-and-shine/

http://blog.salazarpackaging.com/sustainable-packaging/random-repeat-patterns-for-e-commerce-and-subscription-boxes/

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