Have you ever thought about how a simple idea may become the packaging that characterizes a company, such as strong boxes, stylish labels, and eco-friendly mailers? There is a comprehensive packing procedure behind every outstanding product that uses creativity, accuracy, and environmental friendliness.

At Elements Branding Solutions, we always start by learning about the brand, including its product, story, and target demographic. After that, our team makes the concepts come to life by choosing materials, making prototypes, printing, and making the final product. We make sure that it looks beautiful and works well.

We’ll show you how production packing really works, step by step, in this post. You will receive a clear picture of how every box, bag, and label is made with a purpose, whether you run a company and are looking into bespoke packaging or are just curious about what goes on behind the scenes.

What Packaging Production Actually Is

When people talk about production packaging, they mean all the steps that go into making physical packaging on a large scale, from art and engineering. That includes choosing the design, materials, printing, finishing, die-cutting, putting everything together, and mailing it off. In summary, the packing process starts with an idea and finishes with a product that is ready to be shipped.

Here are some facts about the market to help you understand: In 2024, the worldwide packaging market was worth an incredible $1.08 trillion. By 2032, it is expected to be worth $1.45 trillion. That’s huge. Various types of packaging, such as flexible packaging, rigid plastics, paperboard, and specialist categories, all have various jobs. That’s crucial because the choices you make (material, finish, complexity) will affect the cost, how long it takes, and how long it lasts.

The 13 Steps of Package Production

We have broken down our production packaging process into 13 parts at Elements Branding Solutions. Each one is very important for making sure your packing works, lasts, and gets to you on time.

Step 1: Design & Concept Development

An idea is where everything begins. But how can you make that idea into something you can sell? That’s when the actual job starts.

Our design team meets with customers to learn about their brand, product, and ambitions. We’re not simply making nice photographs; we’re fixing things. Does the packaging need to keep a fragile item safe while it’s being shipped? Should it open in a certain way to make the unpacking experience better? What should it say at first glance?

We use software like AutoCAD to make technical drawings that are very accurate, with correct measurements, fold lines, and other details. This is about making sure that the packaging procedure can really make what was planned.

The smart packaging market around the world is predicted to expand from $30.3 billion in 2024 to about $55.6 billion by 2034. Brands are making their packaging more complex; thus, the design and concept creation stage is more vital than ever.

Step 2: Material Selection

The “stock,” which is the industrial term for the material we use, comes in several sorts and thicknesses, which are measured in GSM (grams per square meter).

Common options include:

• Kraft paper – Natural, recyclable, great for eco-friendly brands
• Art card – Smooth finish, excellent for printing
• Corrugated cardboard – Durable, perfect for shipping
• Rigid board – Premium feel for luxury products

The standard GSM is between 210 and 350; however, we can make it heavier by putting together more than one layer. For instance, two 230 GSM cards can be put together to make 460 GSM, which is better for heavy items.

Check this out: In 2023, the Asia-Pacific region had the biggest share of the packaging and production market, with 46.3% of all volumes. We have factories in China, Vietnam, Bangladesh, and Indonesia, which puts us right in the middle of this production hub.

Step 3: Pre-production Planning

We prepare everything, including resources, timelines, and material needs, before production starts. This is called pre-production planning.

Our operations team makes thorough production forms that list all the details, such as sizes, materials, styles, colors, and any special requests from the client. To avoid possible delays, we work with the design, printing, and assembly teams.

Step 4: Plate Making

You can’t just hit “print” on packing as you would on an ordinary document. To print your design, you need to make real plates for each color.

We employ modern CTP (Computer to Plate) technology to make sure everything is right. We make four different plates if your design uses four colors: cyan, magenta, yellow, and black. Each plate puts a different color on the material, and when you put them all together, you get your final full-color pattern.

Because of this level of accuracy, your brand colors look the same on every package—no changes, no surprises.

Step 5: Cutting and Paper Shaping

We need to trim the material to the correct size and form before we can print. Die-cutting machines do this with amazing accuracy, making the folds, slots, and tabs that will eventually make up the structure of your box.

This step lays the groundwork for the next one. If you don’t get the measurements right here, nothing else will fit together right later.

Step 6: Printing

Now comes the moment where design becomes a tangible reality. We offer two main printing technologies:

Offset printing – Ideal for large runs, produces vibrant colors and sharp details
Screen printing – Perfect for specific effects and smaller batches

Brand identity truly comes to life during the printing process. Using high-quality inks and varnishes, everything from logos to product information to artwork is printed on the material.

Food and drinks made up the biggest part of the packaging industry for end-users in 2024. Whether you’re packaging snacks, cosmetics, or electronics, accurate color representation during printing is non-negotiable.

Step 7: Lamination

Food and drinks made up the biggest part of the packaging industry for end-users in 2024. When printing, it’s important to get the colors right, whether you’re packing snacks, cosmetics, or gadgets.

We offer three types:

• Gloss lamination – Shiny, eye-catching finish
• Matt lamination – Sophisticated, modern look
• Soft touch – Premium, velvety texture

The market for eco-friendly packaging around the world is growing quickly. It is expected to go from almost $270 billion in 2024 to around $490 billion by 2034. A lot of our laminating solutions are good for the environment and still protect well.

Step 8: Add-ons

This is where packaging moves from being good to being great. Add-ons are extra characteristics that make things look and feel more luxurious, like texture and depth.

• Embossing & Debossing – Raised or recessed designs you can feel
• Foil stamping – Metallic accents that catch the light
• UV coating – Selective shine on specific design elements

These are strategic branding tools. Premium products demand premium packaging, and these add-ons deliver that elevated experience.

Step 9: Die-making/Die-cutting

We cut the laminated material into its final shape with steel-rule dies that are contoured just so. This makes the exact folds, holes, and cutouts that turn the flat material into a three-dimensional box.

Die-cutting ensures every piece is identical, which is crucial for both functionality and brand consistency.

Step 10: Assembly

Our assembly crew puts together the final package structure by folding, gluing, and building it. This needs competent people who know how to put everything together.

We can send packages flat (for you to put together on-site) or fully assembled and ready to be filled with product, depending on what you need.

Step 11: Quality Control & Testing

We don’t just think the packing will work; we test it. With strictness.

Drop tests are like shipping circumstances. Weight tolerance tests ensure that packages can hold what they are supposed to. Tests of material strength show that it will last.

Our quality control standards are very strict since industries like pharmaceuticals can’t afford to have packaging problems. The global market for pharmaceutical packaging will expand from $146.1 billion in 2024 to $342.2 billion by 2034.

Step 12: Packing

After quality control checks are done, the parcels are put for shipping. This means stacking things carefully, identifying them correctly, and attaching them securely so they don’t get damaged while being moved.

Good packing uses up as much space in the container as possible while keeping things from moving about. This is very important for keeping your production package in pristine shape until it gets to you.

Step 13: Final Inspection & Shipping

Before anything leaves our facility, we check it one more time to make sure it is of good quality, correct, and the right amount. We check everything against the details of your original order.

Then we take care of the paperwork, work with our logistics partners, and make sure that your order gets to you or your distribution center on time.

Common Tradeoffs

When you plan a packaging run, three levers matter most:

• Cost — More colors, special finishes, and low order quantities raise the unit price.
• Lead time — Tooling, die-cutting, and custom finishing add days to the schedule.
• Performance & sustainability — Heavier or coated stocks protect better but may be harder to recycle.

A real-world example: a mailer made of 100% recycled paper looks wonderful for messages about being eco-friendly, but it can cost two to four times as much as a mailer made of recycled poly and may make shipping heavier. On the other hand, recycled poly (PCR) might sometimes have a smaller carbon footprint and last longer for items that get returned a lot. That’s why it’s worth your effort to do tests and comparisons that take LCA into account.

Speed & Scaling: Production Considerations for Fast Growth

If you expect volumes to ramp up, plan for:

• Tooling reuse — can dies be kept and reused for repeat orders?
• Multiple factories / regional hubs — split production geographically to shorten transit and reduce carbon.
• Stock buffers — keep a safety stock of standard SKUs (labels, mailers) for peak seasons.
• Digital printing pilots — for low MOQ or frequent SKU changes, digital print saves time.

To make sure the fit and finish are right, many brands start with a pilot run of 1,000 to 5,000 units. Once the prototype is approved, they move on to mass production.

Quick Checklist to Add to Your Packaging Brief

• Target order qty & expected annual run rate
• Product dimensions and protection needs
• Preferred materials + sustainability targets (PCR% %, FSC, etc.)
• Print (colors, Pantone references) and finish (lamination, foil)
• Prototype sample request timeline
• Acceptance tests required (drop test, seal test)
• Lead time & shipping INCOTERMS

Drop this list into your RFP — suppliers can respond precisely instead of guessing.

Ready to Partner with Elements Branding Solutions?

Brands can make better, faster, and more environmentally friendly decisions if they know how packaging is made. At Elements Branding Solutions, we make those decisions come true with accuracy, originality, and a global supplier network that ensures the quality is high at every step.

Get in touch with our team for prices, samples, or help with your products. You’ll see why top businesses around the world trust Elements Branding Solutions to make their packaging ideas a reality.

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