From artwork file to the first printed roll
Buyers often assume a design file can go straight onto the press. In practice a printed film passes five stages, and each one affects how the finished bag looks and when it ships.
1. Prepress check
Three things get verified first: whether the artwork matches the bag format (the same graphic has a completely different flat size on a three-side seal and an eight-side seal), whether fonts are outlined, and whether image resolution is high enough. A low-resolution image looks fine on screen and turns into visible pixels once it is enlarged on a cylinder.
2. Bleed and imposition
A pouch is a three-dimensional object. On gusseted formats the print stretches at the folds, so the bleed you need depends on the bag structure and the registration capability of the press. That is why we confirm the format at quotation stage rather than after the design is finalised.
3. Cylinder making
Gravure printing uses one cylinder per colour. More colours mean higher cylinder cost and longer set-up, which is why "one colour less saves real money" is a genuine statement in this industry, not a sales line. Above four colours we usually ask which colours are brand-critical and which can be combined.
4. Proofing
A proof run confirms colour, registration and how the material feels. Proofing and production may run on different machines, so a passing proof does not guarantee zero colour shift in mass production, but it keeps the deviation inside an agreed range.
5. Printing and curing
Tension, ink viscosity and drying temperature are controlled during the run. Film pulled too tight deforms; too loose and registration drifts. Ink that is not fully cured can cause odour or poor lamination bond later.
The first three stages decide whether the job can be printed correctly; the last two decide whether it prints consistently. What helps most from the buyer's side: confirm the bag format early, send vector artwork, and tell us which colours are brand colours.
Working on a new pack?
Send us the product and target shelf life. We will help with the structure.