Packaging Design

Design professional product packaging from concept to print

Project Overview

Packaging design combines aesthetics with technical requirements. This guide covers boxes, labels, bags, and other packaging materials.

Time to Complete: 2-6 hours (varies by complexity) Difficulty: Advanced Recommendation: Work closely with packaging manufacturer

Types of Packaging

Folding Cartons (Boxes)

What: Flat cardstock folded into boxes

Common types:

• Straight tuck end (STE)
• Reverse tuck end (RTE)
• Auto-lock bottom
• Gable top
• Pillow box

Materials: Cardstock (12-24 pt)

Printing: Offset or digital

Use for: Product boxes, retail packaging, gift boxes

Complexity: High (requires dielines)

Labels

What: Adhesive labels for bottles, jars, products

Types:

• Roll labels (circular products)
• Sheet labels (flat application)
• Die-cut shapes
• Clear/white materials

Materials: Paper, vinyl, polyester

Printing: Digital, flexo, offset

Use for: Bottles, jars, products, shipping

Complexity: Medium

Bags & Pouches

What: Flexible packaging

Types:

• Stand-up pouches
• Flat pouches
• Gusseted bags
• Paper bags

Materials: Plastic film, paper, foil

Use for: Food, coffee, supplements, retail

Complexity: Medium-High

Sleeves & Wraps

What: Labels wrapping around containers

Types:

• Shrink sleeves
• Pressure-sensitive labels
• Belly bands

Application: Heat-shrunk or glued

Use for: Bottles, cans, jars

Complexity: Medium

Working with Dielines

What is a Dieline?

Definition: Template showing cut/score/fold lines for packaging

Components:

• Die cut lines (solid): Where to cut
• Score/fold lines (dashed): Where to fold
• Safety area: Keep important content here
• Bleed area: Extend design here

Example (simplified box):

┌─────────────────┐
│    ┌─────┐      │  Solid line = Cut
│    │     │      │  Dashed line = Fold
│────┼─────┼────  │
│    │     │      │
│    └─────┘      │
└─────────────────┘

Getting Dielines

1. From Packaging Manufacturer

   Best source: Your chosen packaging supplier

   Request: “Can you provide a dieline template?”

   Format: Usually AI (Illustrator), PDF, or EPS

   Benefit: Exact specifications for their equipment

   ✅ Recommended approach

2. Industry Standard Templates

   Sources:

   • Packhelp
   • Packlane
   • BoxStructure.com
   • ArtiosCAD

   Caution: Verify dimensions match your needs

   Customize: May need adjustment

3. Custom Creation

   Advanced: Create your own in CAD software

   Tools: ArtiosCAD, Boxshot, Cape Pack

   Not recommended: Unless experienced

   Better: Get from manufacturer

Importing Dieline to Figma

1. Receive Dieline File

   Formats: AI, EPS, PDF, or SVG

   From manufacturer or template library

2. Convert if Needed

   If AI/EPS:

   • Open in Illustrator
   • Save as PDF or SVG
   • Export at actual size (100% scale)

   If PDF: Can import directly to Figma

   Important: Preserve dimensions (no scaling)

3. Import to Figma

   Method 1: Drag PDF/SVG into Figma

   Method 2: File → Place Image → Select file

   Result: Dieline imported as vector (if SVG) or image (if PDF)

4. Verify Dimensions

   Critical: Check size matches specification

   Example: If dieline should be 12” × 8”, verify in Figma

   Fix if wrong: Resize to exact dimensions

   Lock: Lock layer so you don’t accidentally move it

5. Organize Layers

   Create layers:

   • Background: Dieline template (locked)
   • Design: Your artwork (editable)
   • Guides: Cut/fold/safety lines (reference)

   Lock dieline: So you don’t modify it

   Design above: Create artwork on top

Box Design Specifications

Common Box Sizes

Product Type	Typical Box Size	Cardstock Weight
Small item (jewelry)	2” × 2” × 1”	18-24 pt
Standard product	4” × 4” × 2”	16-20 pt
Food box	6” × 4” × 3”	18-24 pt
Large retail	10” × 8” × 4”	20-28 pt
Shipping box	Various	200+ lb test (corrugated)

Critical Zones

Bleed

Amount: 0.125” (3mm) beyond die cut line

Why: Ensures no white edges after cutting

Extend: All background colors/images to bleed

Example:

Die cut ──→ │ ← 0.125" bleed extends beyond

Check: All edges have bleed

Safety Zone

Amount: 0.125-0.25” (3-6mm) inside die cut

Why: Cutting tolerance, folding distortion

Keep inside:

• All text
• Logos
• Important graphics
• Barcodes

Avoid: Critical content at fold lines

Example:

Die cut ──→ │ ←── 0.25" safety
            │ [SAFE AREA FOR TEXT]

Fold Lines

Marking: Dashed or dotted lines

Process: Score lines created during die-cutting

Design consideration:

• Avoid placing important text on folds
• Keep 0.125” clear on each side of fold
• Design may shift at fold

Test: Print and fold mock-up

Glue Tabs

What: Flaps where adhesive is applied

Keep clear: No important content

Usually: Plain or simple pattern

Marked on dieline: Shows where glue goes

Design: Background color/pattern only

Label Design

Label Types & Specifications

Bottle Labels (Cylindrical)

Shape: Rectangle wrapping around bottle

Measurements needed:

• Bottle circumference
• Label height
• Overlap (0.25-0.5”)

Example (3” diameter bottle):

Circumference = π × D = 3.14 × 3" = 9.42"
Label width = 9.42" + 0.5" (overlap) = 9.92"

Considerations:

• Seam placement (usually back)
• Label curls with bottle
• Front panel prominent

Format: Rectangular with bleed

Die-Cut Labels

Shape: Custom shape following product

Examples:

• Circular
• Oval
• Custom logo shape
• Irregular shapes

Design:

• Dieline defines shape
• Bleed extends beyond cut
• Safety margin inside

Popular for: Premium products, branding

Front & Back Labels

Configuration: Two separate labels

Front label:

• Product name
• Brand
• Key visual

Back label:

• Ingredients/info
• Barcode
• Regulatory text

Common for: Food, beverages, cosmetics

Label Materials

Paper (Uncoated)

Characteristics:

• Natural texture
• Matte finish
• Absorbs ink

Best for: Craft products, organic, eco-brands

Not for: Wet/refrigerated products

Paper (Coated)

Characteristics:

• Glossy or matte coating
• Vibrant colors
• Water-resistant coating option

Best for: Most products, retail

✅ Most common

Vinyl

Characteristics:

• Waterproof
• Durable
• Flexible

Best for: Outdoor, wet environments, bottles

Cost: Higher than paper

Clear/Transparent

Characteristics:

• See-through background
• Product visible through label
• Premium look

Best for: Glass bottles, luxury products

Design: Plan for transparency

Color & Printing Considerations

Pantone for Brand Consistency

Why Spot Colors Matter

Problem: Packaging requires exact brand colors

Solution: Use Pantone spot colors

Benefits:

• Consistent across production runs
• Matches brand guidelines
• Vibrant colors beyond CMYK

Essential for: Brand colors, logos

See Spot Colors Guide

Spot + CMYK

Common approach:

• CMYK for images/photos
• Spot color for logo/brand elements

Example:

Plates:
1. Cyan (CMYK)
2. Magenta (CMYK)
3. Yellow (CMYK)
4. Black (CMYK)
5. Pantone 287 C (brand blue)
= 5-color printing

Cost: More than 4-color, but worth it for brand accuracy

All Spot Colors

When: Simple design, 2-3 colors

Example: White box + 2 Pantone colors

Benefits:

• Lower cost (fewer plates than CMYK + spot)
• Perfect color match
• Clean, simple

Use for: Minimalist packaging

Special Finishes

Spot UV

Effect: Glossy coating on specific areas

Application: Matte base + gloss highlights

Use for: Logos, text, patterns

Feel: Tactile, premium

Cost: Moderate add-on

Foil Stamping

Effect: Metallic foil adhered to paper

Colors: Gold, silver, copper, holographic

Application: Hot stamping

Use for: Luxury packaging, premium brands

Cost: Higher

Embossing/Debossing

Effect: Raised (emboss) or depressed (deboss) areas

Application: Die stamp

Can combine: With foil

Use for: Logos, premium packaging

Cost: Higher (requires custom die)

Matte/Gloss Lamination

Effect: Overall coating

Matte: Soft, sophisticated

Gloss: Vibrant, eye-catching

Protection: Moisture and scuff resistance

Cost: Low add-on

✅ Common and affordable

Regulatory Requirements

Food & Beverage Packaging

Legal requirements vary by country and product type

Always consult:

• Food safety regulations
• Labeling laws
• Industry guidelines
• Legal professional if unsure

Common requirements (US/FDA):

• Product name
• Net quantity
• Ingredient list (in order)
• Allergen warnings
• Nutrition facts
• Manufacturer info
• Country of origin
• Lot/batch code
• Expiration date

Font sizes: Minimum sizes required

Placement: Specific locations mandated

Get review: Legal/compliance check before printing

Barcodes

UPC/EAN Barcode

Required for: Retail sales

Obtain from: GS1 (gs1.org)

Size: Minimum 1.469” × 1.02” (UPC-A at 100%)

Placement:

• Bottom right (preferred)
• Clear space around (quiet zone)
• White background

Quality: High resolution, vector if possible

Test: Scan before mass production

QR Codes

Use for:

• Website links
• Product information
• Promotions

Size: Minimum 0.75” × 0.75”

Contrast: Dark code on light background

Test: Scan to verify functionality

Generate: QR code generator tools

Mock-Ups & Proofing

Physical Mock-Ups

1. Print Flat

   Print dieline with your design at actual size

   Printer: Home or office printer OK for mock-up

   Paper: Regular paper fine for testing

2. Cut and Fold

   Cut: Along die cut lines

   Score: Use ruler and bone folder on fold lines

   Fold: Assemble box/package

3. Evaluate

   Check:

   • Does it fold correctly?
   • Content in right places?
   • Text readable?
   • Design looks good assembled?
   • Any issues at folds?

   Adjust: Fix issues in Figma, repeat

Digital 3D Mock-Ups

Tools:

• Boxshot
• Packly
• Adobe Dimension
• Online mock-up generators

Benefits:

• Realistic rendering
• Multiple angles
• Client presentations
• Marketing images

Limitation: Not a substitute for physical mock-up

Printing & Production

Minimum Order Quantities

Package Type	Typical MOQ	Cost Range
Custom boxes	1000-5000	$0.50-3.00 each
Labels (roll)	500-1000	$0.05-0.50 each
Pouches/bags	1000-5000	$0.20-1.00 each
Short-run digital	100-500	Higher per-unit

Digital printing: Lower MOQ, higher unit cost

Offset printing: Higher MOQ, lower unit cost

Lead Times

Design approval: 1-2 weeks

Die creation (if new): 1-2 weeks

Printing: 1-3 weeks

Shipping: 1-2 weeks

Total: 4-8 weeks typical

Rush options: Available at premium cost

Step-by-Step: Simple Box

1. Get Dieline from Manufacturer

   Contact packaging supplier, request dieline template

   Receive AI, PDF, or SVG file

2. Import to Figma

   Create frame matching dieline dimensions

   Import dieline as background layer

   Lock dieline layer

3. Add Guides

   Mark:

   • Die cut lines
   • Fold lines
   • Safety zones (0.25” inside)
   • Bleed areas (0.125” outside)

   Use Figma guides or shapes

4. Design Panels

   Identify panels:

   • Front
   • Back
   • Sides
   • Top/bottom flaps

   Design each panel:

   • Brand elements
   • Product info
   • Graphics

   Respect: Safety zones, fold lines

5. Add Regulatory Elements

   Include (if applicable):

   • Barcode
   • Ingredients
   • Warnings
   • Certifications
   • Contact info
6. Extend to Bleed

   Ensure: All backgrounds/colors extend 0.125” beyond die cut

   No white gaps: After cutting

7. Export

   Printery:

   • CMYK conversion ✓
   • Spot colors (if used) ✓
   • 300 DPI ✓
   • Crop marks ✓

   Submit: PDF to manufacturer

   Include: Printing specifications

8. Proof Before Production

   Request: Physical proof from printer

   Verify:

   • Colors accurate
   • Folds correctly
   • No errors

   Approve: Before full production run

Packaging Design Checklist

• Dieline obtained: From manufacturer or verified source
• Dimensions verified: Matches product and specifications
• Bleed added: 0.125” (3mm) beyond cut lines
• Safety zones respected: 0.25” (6mm) inside cut/fold lines
• All text readable: Minimum 8pt, larger for regulatory
• Fold lines clear: No important content on folds
• Colors specified: CMYK or Pantone as appropriate
• Special finishes noted: UV, foil, emboss (if applicable)
• Regulatory compliance: All required information included
• Barcode included: Correct size, placement, scannability
• Physical mock-up created: Printed, cut, folded, tested
• Images 300 DPI: All graphics high resolution
• Manufacturer specs met: Confirmed requirements
• Proof approved: Physical sample checked before production

Learn More

Spot Colors

Brand color accuracy with Pantone

Color Management

Professional color workflows

Advanced Options

Custom configurations

Design to Print

Professional design principles

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Pro Tip: Always, always, ALWAYS order a physical proof before mass production. The $50-100 proof cost can save you from$5,000+ in wasted packaging!