PackRapid Design File Submission Guide: How to Prepare Files for Optimal Production

Introduction: A perfect packaging design starts with excellent design and culminates in fine production. The key bridge connecting design and production is accurate and standardized design files. Non-standard or incomplete files often lead to production delays, deviations, and even increased costs. To ensure that your design concepts can be accurately and flawlessly transformed into high-quality physical packaging by PackRapid's production team, we have prepared this detailed design file submission guide for you. Following these recommendations will help us collaborate more efficiently and together create the best production results that satisfy you.

I. File Format and Software: Basic Standards

• Preferred Formats:
  • Adobe Illustrator (AI): Vector graphics software, the industry standard for packaging structure and flat design. Please provide the original .ai file.
  • Adobe PDF (High-Resolution Print Output): PDF files exported from AI or other professional software. All fonts and linked images must be embedded, and editing capabilities (if possible) should be preserved.
• Other Acceptable Formats (Requires prior communication with PackRapid):
  • CorelDRAW (CDR)
  • Adobe InDesign (INDD) - Usually used for multi-page brochures, less for packaging.
  • High-resolution PSD, TIFF, EPS (for bitmap images).
• Formats to Avoid:
  • Word, Excel, PowerPoint, and other office software formats.
  • Low-resolution JPG, PNG, GIF, and other web image formats.

II. Die-cut Diagram (Structural File): The Skeleton of the Packaging

The die-cut diagram is the direct basis for packaging structure production, and its accuracy is crucial.

• Content Requirements:
  • Clear Line Distinctions:
    • Cutting Line: Usually represented by a solid line, defining the final outline of the packaging.
    • Creasing/Scoring Line: Usually represented by a dashed line or a solid line of a specific color (e.g., red), indicating the folding position. Please clearly distinguish the representation of inside folds (mountain folds) and outside folds (valley folds), or label them separately in layers.
    • Perforation Line: If any, it must be clearly marked.
  • Precise Dimensional Annotation: Label all key dimensions (length, width, height, glue flaps, etc.), with units uniformly in millimeters (mm).
  • 1:1 Ratio: The die-cut diagram must be drawn at 100% actual size.
  • Bleed: The color or pattern of the design should extend 3-5 mm beyond the cutting line to avoid white edges during cutting. Please indicate the bleed line in the die-cut.
  • Safety Margin: Important text and graphic elements should be placed at least 3-5 mm inside the cutting line to avoid being cut or being too close to the edge.
  • Glue Flap/Adhesive Flap: Clearly indicate the glue flap position and size; usually, no content is printed here.
  • Die-cuts Provided by PackRapid: If you are unsure how to create a die-cut, you can send your product dimensions or physical sample to PackRapid, and our structural engineers can design and provide professional die-cut files for you.

III. Design Draft (Printing File): The Face of the Packaging

The design draft determines the visual presentation of the packaging.

• Color Mode:
  • CMYK: All colors used for printing must be set to CMYK mode. RGB colors may have significant color shifts when converted to CMYK.
  • Spot Color (Pantone Color): If spot colors are used, please clearly indicate the Pantone color number (e.g., PANTONE 185 C/U) and use the corresponding spot color palette in the file. Spot colors should be marked in separate layers or channels.
• Image Elements:
  • Resolution: All embedded bitmap images (photos, background images, etc.) should have a resolution of at least 300 DPI (at the actual printing size). Insufficient resolution will result in blurry printing.
  • Linking and Embedding: It is recommended to embed all linked images into the AI or PDF file, or to package the linked images together with the main file.
  • Black Treatment:
    • Small-sized Black Text: It is recommended to use single-color black (C0 M0 Y0 K100).
    • Large-area Black: To achieve a richer, fuller black effect, it is recommended to use four-color black (rich black), such as C40 M30 Y30 K100 (specific values can be confirmed with PackRapid to avoid excessive total ink).
• Text Elements:
  • Create Outlines: To avoid errors or deformation in text display due to missing fonts, please create outlines (convert to outlines) for all text content. If you want PackRapid to modify the text, please provide the font files used.
  • Minimum Font Size: Avoid using excessively small font sizes, especially for reverse white text or text on complex backgrounds, to prevent unclear printing. Consult PackRapid for specific minimum font size recommendations.
• Overprint and Transparency:
  • Overprint Preview: Please enable overprint preview in the design software to check for unexpected overprint effects.
  • Transparency Flatten: If transparency, shadows, or feathering effects are used, it is recommended to perform appropriate transparency flattening when exporting the final printing file, or confirm the best processing method with PackRapid.
• Special Process Marking:
  • Hot stamping, UV, embossing, etc.: If special processes are involved, please clearly indicate the process area and content in the design draft using a spot color (such as PANTONE Reflex Blue U) or a separate layer, and provide the corresponding black and white draft (K100). The process file must be accurately aligned with the printing file.

IV. File Organization and Submission

• File Naming: Clearly and consistently name files, such as "Project Name_Box Type_Size_CMYK.ai", "Project Name_Box Type_Size_Hot Stamping.ai".
• Layer Management (AI files): It is recommended to manage layers for die-cut lines, bleed lines, design content, special processes, etc., to facilitate PackRapid's identification and processing.
• Packaging and Submission:
  • Organize all relevant files (AI/PDF main files, linked images, font files, process files, effect reference images, etc.) into a single folder.
  • Compress the folder (e.g., .zip or .rar format) and send it to PackRapid's contact person via email, FTP, or cloud storage.
  • Please include a detailed production requirement description (such as quantity, materials, process, delivery date, etc.).

V. Final Checklist (Checklist Before Submission)

• [ ] Is the file format correct?
• [ ] Is the die-cut diagram at a 1:1 ratio, and are the dimensions clearly and accurately marked?
• [ ] Are the bleed and safety margins properly set?
• [ ] Is the color mode CMYK (or spot colors clearly indicated)?
• [ ] Is the image resolution sufficient (≥300 DPI)? Are the images embedded or provided together?
• [ ] Has all text been converted to outlines (or font files provided)?
• [ ] Are special process areas clearly marked?
• [ ] Are file names and layers standardized?
• [ ] Are all necessary files included and packaged?
• [ ] Are detailed production requirements included?

Conclusion: A well-prepared, standardized, and accurate design file is the cornerstone of efficient and high-quality production. PackRapid hopes that this guide will help you better understand the specific file requirements for packaging production. Of course, if you have any questions during the file preparation process or are unsure about certain technical details, please feel free to contact PackRapid's professional customer service or technical support team. We are happy to assist you to ensure your design concepts are perfectly presented. Let's work together, starting with standardized files, to create stunning packaging that enhances your brand!