Litho-laminated corrugated packaging is one of the most visually appealing types seen on store shelves. It is made by bonding a lithographically printed sheet to a corrugated single-face substrate, creating a high-quality print surface over a structural board. Cost problems usually occur when graphics, structure, materials, run size, assembly, and distribution requirements are handled as separate decisions. The following design mistakes can add cost before production, during pack-out, and throughout the supply chain.
Designing Litho-Laminated Corrugated Packaging Without Considering Run Size
Volume is an important consideration with litho-lamination because each design requires printing plates, which add upfront costs regardless of the run size. As a result, the unit price decreases as volume increases. Litho-lamination may not be the right choice for small runs or for programs with frequent updates. Litho works best when designs are stable, and there is enough volume to absorb the upfront costs.
Graphic Designing in a Silo
When artwork is created before the board grade, flute profile, and packaging dimensions are finalized, the result diminishes the design’s aesthetics. When graphics land on folds, scores, glue flaps, or panel breaks, important text and images can become distorted. This can increase costs because files will need to be revised after engineering review, leading to additional design time, new proofs, delayed approvals, and, in some cases, new printing plates.
Selecting the Wrong Flute Profile
A finer flute size will provide a smoother print surface, but the strength is not as great as that of a larger flute. A large flute size provides greater protection but may affect print appearance. While the high-resolution litho sheet can look pristine, the waviness of the flutes underneath causes a visual defect known as flute telegraphing or washboarding. Paper sinks into the gaps between the flutes when pressure is applied during lamination or folding. The uneven, shadowed ridges are most noticeable in solid-color blocks or in areas with heavy ink coverage.
If the board is too light, packages may fail compression testing or suffer damage in transit, leading to replacement costs and redesigns of packaging. If the board is heavier than required, not only may the visual appearance be impacted, but material costs will increase on every unit produced.
Designing the Litho-laminated Corrugated Packaging Without Considering the Whole System
Litho-laminated corrugated packaging is often used for retail products. Those products may be shipped in a master carton, which will be palletized and move through warehouse operations and retail replenishment processes. The retail packaging must work efficiently within the full system. Decisions made at the retail packaging level can impact material use, freight efficiency, and handling costs throughout the supply chain.
For example, slightly oversized retail packaging may require a larger master carton, reducing the number of cartons that fit on a pallet and, in turn, a truckload. Even small dimensional changes can affect pallet density, storage capacity, and transportation costs. Evaluating the retail packaging as part of the entire packaging system helps identify opportunities to avoid unnecessary costs before production begins.
Using Premium Finishes Without a Clear Purpose
Litho-laminated packaging supports a wide range of enhancements, including coatings, embossing, and specialty finishes. Spot UV, embossing, foil stamping, and specialty coatings can add value in some cases. In others, they increase costs without effective purchasing decisions. For example, applying UV coatings to internal panels, adding premium coatings to non-consumer-facing surfaces, or treating all SKUs like flagship product packaging. If the finish doesn’t influence shelf appeal or purchasing decision, they are increasing packaging spend without providing measurable value.
Designing without Considering Assembly and Packout
Packaging decisions extend beyond the packaging itself and affect operations downstream. Some packaging designs look impressive but require excessive labor to assemble and fill in production or to stock in stores. Some common issues are complex structures that slow down packing, multipiece designs that require time-consuming manual assembly, and inserts that increase labor time and introduce variability. If packaging requires excessive folding, taping, or gluing, labor costs increase every time the package is assembled. A few extra seconds can add up across a significant product volume.
Litho-laminated packaging needs to support consistent, efficient pack-out as much as it supports branding. Packaging should align with how products are actually packed and shipped, not just how they look.
Applying the Same Design Across Channels
Branding requirements often drive the design of litho-laminated packaging. However, the product may be sold through different distribution channels, each with different demands on the packaging. Today, many large online retailers have green initiatives to reduce waste and lower their carbon footprint. This has resulted in Ships in Own Container (SIOC) or Ships in Product Packaging (SIPP)programs. Packaging for retail shelves that focuses on shelf presence and visual impact may not be sufficient for e-commerce, which requires durability and transit protection. Packaging design should reflect how the product is sold and handled, not just how it is branded.
Waiting Too Long To Involve The Packaging Manufacturer
One of the most expensive packaging mistakes is waiting until the design is nearly complete before involving the packaging manufacturer. Many projects begin with a product concept, graphic design, and packaging designs already established. While it may seem efficient, it can limit opportunities to make cost-saving improvements, such as reducing material use or simplifying pack-out design. A package that looks good on screen may require modifications once structural requirements, printing considerations, and production constraints are evaluated.
Early collaboration allows packaging engineers to identify potential issues before they become costly changes. Making changes during the design phase is generally less costly than later in the process, after artwork approvals and tooling and printing plates are made. In many cases, involving the manufacturer early can reduce material costs, improve production efficiency, and avoid project delays caused by redesigns late in the development process.
Talk With Atlas Packaging About Litho-Laminated Corrugated Packaging
If you are developing litho-laminated corrugated packaging for a retail product, bring Atlas Packaging into the process before the design is finalized. Our team can review the structure, graphics, board grade, finishes, assembly requirements, and shipping needs to ensure the package functions as a complete system.
Contact Atlas Packaging to discuss your litho-laminated corrugated packaging project.
