Instructions for preparing a base and lid box file

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Basic File Preparation Rules

  • File format: PDF.
  • Resolution: 300 DPI.
  • Colors: Preferred mode is CMYK (Coated Fogra 39 profile). RGB files will be automatically converted, which may lead to color shifts.
  • Rich black: To achieve rich black, use the following components: C:30% M:30% Y:0% K:100%.
  • Bleed: Add 3 mm of background graphics on each side beyond the target format (e.g., for an 88 x 63 mm card, the file should be 94 x 69 mm).
  • Safety margin: Place important texts and graphics at least 4 mm from the edge of the target format (trim size).
  • Text: All fonts must be converted to outlines.
  • Marks: Do not add cut lines or registration marks when saving.
  • Flatten layers before saving. Remove transparent effects.

The provided mockups contain 4 outlines. The two upper outlines are for the box wrap. This is where you will place the box graphics.

Box production uses cardboard with a thickness of 1 to 2 mm (depending on box size), which has already been accounted for in the die-cut dimensions, so you do not need to calculate wall thickness yourself.

When designing, focus on two specific layouts:

    • Wrap Lines (Base and Lid): These are the two mockups located at the top of the provided template files. This is the actual working area. The wrap is paper that will be glued onto the cardboard and folded inwards.
    • Distinguishing Elements: Remember that the lid is always slightly larger than the base. Make sure you design the graphics on the correct die-cut templates for the top and bottom of the box.

Due to the laminating process (cardboard wrapping), the fitting tolerance is approximately 1–1.5 mm. This should be taken into account when designing the box sides.

    • Bleed: Graphics must extend beyond the die-cut line by a minimum of 3 mm. The entire area inside the die-cut outline, including the bleed, must be filled with background graphics.
    • Safe Area (margin): Place important elements (texts, logos, codes) a minimum of 4 mm from the cut line and fold lines.
    • Avoid Sharp Cut-offs: A common mistake is changing the color of the box’s background graphics exactly at the fold line (box edge).
    • Recommendation: If the front of the box has a different color than the sides, “extend” the front graphic by a minimum of 1.5 mm onto the sides. This way, even with minimal machine misalignment, a strip of the side color will not appear on the box front.

Please generate a set of three files:

  1. Production File: Clean graphics with bleed, without the die-cut grid applied.
  2. Preview File: Graphics with the die-cut grid applied (used by the operator to verify element placement).
  3. Die-cut File: Only the die-cut outline used for design.

File Naming: To avoid errors, name the files strictly according to the scheme: Surname_Dimensions.

    • Kowalski_grafika_300x300x70.pdf (Production File)
    • Kowalski_projekt_300x300x70.pdf (Preview File)
    • Kowalski_siatka_300x300x70.pdf (Die-cut File)

Not sure if your file is prepared correctly?

Submit it to us using the form below. We’ll review it and let you know if everything is correct or if there’s anything we can improve.

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