design

Dieline design, graphic preparation, prepress, and plate making for flexographic printing

Services for Print File Design and Prepress Preparation

In this unit, packaging design services are provided from dieline development to graphic execution, print file preparation (prepress), and delivering standard outputs for flexographic printing. Color selection, design repeat, halftone adjustments, trapping, and ink management are set according to the film type and subsequent processes (lamination, sealing).

Print File Design

Do you have a project in mind? You can send us a message or contact us directly.

Packaging Design and Print File Preparation

Scope of Design Services

– Graphic design for flexible packaging and pouches (Stand-up, Three-side seal, Center seal, Side-gusset)
– Dieline design and adjustment according to pouch type and sealing path
– Flexographic print file preparation: color separation, trapping, overprint, minimum line thickness
– Color management: CMYK and Spot (Pantone) based on printing substrate
– Barcode and mandatory information control (GS1, nutrition facts, date coding)
– Plate making (optional) and delivery of the final file to the printing line

Deliverables We Provide

– Final print file (AI / PDF/X-1a) with all fonts outlined
– Dieline file (DXF/AI/PDF) with standard naming, prepared in Spot and Overprint
– Color separation sheets + ink/color chart
– PDF preview for client approval + layout and repeat guide

Execution Process (6 Steps)

1. Receiving the brief and product details (dimensions, material, sealing/lamination method)
2. Designing or redesigning the dieline and structural approval
3. Graphic design aligned with brand identity
4. Prepress: color separation, halftone, trapping, color profile, barcode check
5. Sending digital proof and obtaining final approval
6. Delivering the standard file and, if required, plate making

Technical Requirements Table for Print Files

Item	Requirement/Description
File Format	AI or PDF/X-1a:2001 (Images Embedded, Fonts Outlined)
Color	CMYK or Pantone Spot; Total Ink Coverage (TAC) max ≈ 280% depending on substrate
Recommended Profile	Fogra39 / ISO Coated v2 (for initial guidance) – final adjustment per printing line
Image Resolution	Minimum 250–300 dpi at 1:1 scale
Bleed & Safe Area	3–5 mm bleed; 3–5 mm safe margin from seal/cut lines
Trapping & Overprint	General trapping 0.1–0.2 mm; Black text Overprint; Registration only for marks
Minimum Line/Text Thickness	Positive line ≥ 0.3pt, Negative line ≥ 0.4pt; Negative text usually ≥ 6pt (legibility)
Barcode	According to GS1; Quiet Zone minimum 2.5 mm; print direction parallel to film flow
Design Repeat	Based on press cylinder length; currently around 400–800 mm (40–80 cm)
Dieline	As Spot Color with clear naming (e.g., DIE), set to Overprint, separated from artwork

Your Frequently Asked Questions

For file review and to receive a customized checklist for the printing line, please contact the design department.

In what format should we deliver the final file?

AI or PDF/X-1a with fonts outlined and images embedded.

What is the maximum number of printable colors?

Up to 8 colors (CMYK + Spot). Color planning is carried out based on the design.

Can Pantone colors be used?

Yes; Pantone is recommended for brand colors or large uniform areas.

What is the minimum size for reverse (knockout) text?

For legibility in flexo printing, usually 6 pt or larger.

Do you provide the dieline?

Yes; based on the pouch type, sealing path, and final dimensions.