Printing on custom packaging

Printing on custom packaging: Cost Guide about Pantone vs CMYK printing. APP’s guide compares color accuracy, cost & hybrid solutions. Color Accuracy Showdown: Pantone Consistency vs CMYK Flexibility. Request more info and free printed samples with MOQ 0!

Printing on white paper

Colors of original paper

Printing on custom packaging CMYK VS Pantone

Pantone uses pre-mixed inks for precise, consistent colors (ideal for logos/branding), while CMYK blends cyan, magenta, yellow, and black to create hues (cost-effective for multi-color designs).
Color accuracy: Pantone guarantees exact matches across materials; CMYK may vary due to ink mixing and printer calibration.
Cost and complexity: Pantone requires separate plates/inks, raising costs; CMYK uses standardized process printing for affordability.
Application: Choose Pantone for critical brand colors, metallic/fluorescent effects, or single-color projects; opt for CMYK for photorealistic prints or budget-sensitive bulk jobs.
Hybrid solutions: Combine both (e.g., Pantone for key brand elements + CMYK for background art) to balance vibrancy, consistency, and cost.

Can color discrepancy be 100% avoided in custom boxes?

Physically impossible! But control it with these 5 proven solutions:

1. Source identical material/ink batches
2. Use consistent printing equipment & team
3. Apply uniform finishing (lamination/coating)
4. Maintain identical inspection standards
5. Choose stable colors (e.g., black + embossed logo)

How to improve the color difference about printing on custom packaging

1. Standardize Color Proofing

Pantone Matching: Require physical Pantone swatches for all brand colors
Digital Mockups: Share screen-accurate proofs with suppliers before production
Batch Alignment: Use master reference samples across all printing runs

2. Optimize Materials & Techniques

Paper Choice: Select coated stocks for sharper color reproduction
Print Method: Use offset printing for solid colors; avoid CMYK blends for critical hues
Ink System: Specify single-pigment inks to minimize metamerism

3. Implement Batch Testing

Lighting Checks: Verify colors under D65 daylight + store lighting
Supplier Calibration: Jointly adjust press settings for substrate absorption rates
ΔE Monitoring: Track color deviation (accept ≤1.5 ΔE)

4. Post-Production Verification

Spectrophotometer Scans: Measure 3+ random boxes per batch
QC Light Booth: Check for metamerism (color shifts under different lights)
Document Variances: Create visual tolerance guides for acceptable ranges

5. Continuous Improvement Loop

Color Database: Log all batch results with photos/measurements
Quarterly Reviews: Analyze trends with suppliers to refine processes
Preventive Adjustments: Modify artwork trapping/overprints based on historical data

Applications on Packagings

More Info & Videos

10 FAQ of Printing

Plate & Setup Costs

Q: Do custom packaging boxes require CTP plates? Cost?
A: Offset printing requires CTP plates: $85-120/color (size-dependent). Digital printing eliminates plate fees.
Q: Is makeready fee charged for printed boxes?
A: Yes! $220-380 per job covers:
- Ink calibration
- Registration alignment
- Waste sheets (first 100-300 sheets)

Color Systems & Pricing

Q: CMYK vs Pantone cost difference for custom boxes with logo?
A:
Method Setup Cost Per Unit Cost
CMYK $0 $0.003/cm²
Pantone Spot $120/color $0.007/cm²
4C + 1 Pantone $120 $0.009/cm²
Q: Premium custom color options beyond Pantone?
A: Metallic inks (+40%), fluorescent pigments (+65%), thermochromic (+$0.08/cm²) – MOQ 5,000+ units.

Method	Setup Cost	Per Unit Cost
CMYK	$0	$0.003/cm²
Pantone Spot	$120/color	$0.007/cm²
4C + 1 Pantone	$120	$0.009/cm²

Color Accuracy Control

Q: How to reduce color variance in custom print runs?
A: Implement:
- G7 calibration (ΔE<1.5)
- Spectrophotometer QC every 500 sheets
- Standardized D50 lighting for approvals
  Reduces rejects by 83%
Q: CMYK to Pantone conversion accuracy?
A: 85% match within ΔE<3.0 – critical colors (logos) require spot Pantone for ΔE<1.0 precision.

Material-Specific Challenges

Q: Why do kraft customised boxes show color shifts?
A: Brown substrate alters hues. Solutions:
- White underbase layer (+$0.05/unit)
- Double-hit printing
- Pantone 873C/874C (optimized for kraft)
Q: Envelope printing color consistency issues?
A: Woven textures cause dot gain variations. Use:
- Smooth-coated envelopes
- Reduced ink density (280% max TAC)
- Digital printing (avoids dot gain)

Cross-Platform Branding

Q: Matching custom business cards to printed boxes?
A: Require:
- Shared ICC profile
- Identical substrate whiteness (≥92 CIE)
- Batch-controlled inks
  Achieves ΔE<1.5 across materials
Q: Custom card printing for packaging inserts?
A: Use same Pantone references as main box – specify exact paper stock (e.g., 270gsm Mohawk Superfine).