How to Prepare Graphic Design for Printing?

How to properly prepare design for printing on packaging?

Preparing graphic design for printing on packaging differs significantly from preparing files for paper printing or advertising materials. Packaging has a three-dimensional construction, requires precise bleeds, specific color settings, and must meet technical standards for the given printing technology.

In this guide, we'll walk you through the entire process step by step — from downloading the technical template to exporting the final production file. Whether you're commissioning design from a graphic designer or preparing it yourself, this article will help you avoid the most common mistakes and save time and money.

If you're interested in broader context about printed packaging, see our complete guide.

Step 1: Download technical template

Every packaging has unique dimensions, print zones, cut and fold lines. Therefore, the first step is always contacting the printer and downloading a technical template.

What does the technical template include?

• Cut line (die-line): packaging outline when unfolded flat
• Bleeds: safety zone beyond the cut line (3-5 mm)
• Safety zone: inner area where key elements are not placed (5-8 mm from cut line)
• Crease lines: packaging fold locations
• Glue areas: zones that will be sealed (do not print graphics)
• Web direction: print orientation on the machine

Popular template formats

• Adobe Illustrator (.ai): most commonly used — layers with technical lines
• PDF (.pdf): universal, but requires manual layer separation
• ArtiosCAD (.ard): professional format for cardboard packaging

Why is the template crucial?

Designing without a template is the most common mistake leading to:

• Graphics overlapping glue zones

• Text cut off at the cut line

• Reversed or shifted elements on finished packaging

• Costly corrections and production delays

Step 2: Set CMYK color space

Printing on packaging is done in CMYK color space (Cyan, Magenta, Yellow, Key/Black), not RGB. This is a fundamental difference that, if ignored, leads to disappointing results.

Why CMYK and not RGB?

• RGB is an additive model (light) — used on screens

• CMYK is a subtractive model (pigment/ink) — used in printing

• RGB colors have a wider gamut than CMYK — some intense shades (neon, bright) are unachievable in print

How to properly set up CMYK?

1. New document: create in CMYK from the start (don't convert from RGB at the end)

2. ICC profile: use a profile dedicated to the substrate — the printer should provide it. If you don't have a profile, use ISO Coated v2 300% (paper printing) or FOGRA39 (European standard)

3. Imported photos: convert in Photoshop (Edit > Convert to Profile > CMYK)

4. Spot colors (Pantone): define in Swatches palette as Spot Color, don't convert to CMYK

When to use spot colors (Pantone)?

Spot colors are indicated when:

• Company logo requires precise reproduction of a specific shade

• Color outside CMYK gamut is required (e.g., Pantone 021 orange)

• Metallic colors (Pantone Metallic) or fluorescent colors are needed

• You're printing in 1-2 colors (cheaper than full CMYK)

Remember that each additional spot color is an additional printing section and additional cost. Read more about how colors affect price in our article packaging pricing.

Step 3: Prepare graphics at 300 DPI resolution

Graphic file resolution directly affects sharpness and print quality.

Resolution requirements

Element type	Minimum resolution	Recommended resolution
Photos and textures	300 DPI	300-400 DPI
Line graphics (1-bit)	600 DPI	1200 DPI
Barcodes (EAN, QR)	600 DPI	600-1200 DPI
Logo (raster)	300 DPI	Vector (preferred)
Small text (below 6 pt)	600 DPI	Vector (required)

How to check resolution?

• Adobe Illustrator: Window > Links > click image > Effective PPI
• Adobe Photoshop: Image > Image Size > Resolution (at 100% scale)
• CorelDRAW: click bitmap > status bar shows DPI

Watch out for scaling

Resolution is inversely proportional to scale:

• 300 DPI image scaled to 200% = effectively 150 DPI (too low)

• 300 DPI image scaled to 50% = effectively 600 DPI (ok, but unnecessarily large file)

• Rule: check Effective PPI, not nominal

Vector graphics — gold standard

Whenever possible, use vector graphics (AI, EPS, SVG):

• Logo, icons, geometric patterns — always vector

• Typography — always vector (converted to outlines)

• Illustrations — vector if style allows

• Photos — only element that must be raster

Step 4: Add 3-5 mm bleeds

Bleeds are graphic extensions beyond the packaging cut line. They are essential to avoid white strips at edges after cutting.

Bleed requirements by technology

Printing technology	Minimum bleed	Recommended bleed
Digital printing	3 mm	3 mm
Flexography	3 mm	3-5 mm
Rotogravure	5 mm	5 mm
Offset (cardboard)	3 mm	3-5 mm

How to properly set up bleeds?

1. When creating document: Document Setup > Bleed: 3 mm (or 5 mm)

2. Extending background: background must extend beyond cut line by bleed value

3. Repeating patterns: check that pattern connects properly in bleed zone

4. Full-bleed photos: crop with bleed margin — don't stretch

Safety zone

In addition to external bleeds, remember the internal safety zone:

• Text: minimum 5 mm from cut line
• Logo and key elements: minimum 5-8 mm from cut line
• Barcodes: minimum 5 mm from edges and folds
• Legal information: in safety zone, away from edges

Step 5: Check fonts and outlines

Font problems are one of the most common causes of production errors. The solution is simple: convert all fonts to outlines (curves).

What is converting to outlines?

Converting font to outlines (Type > Create Outlines in Illustrator) converts text from editable font to independent vector shapes. The file no longer requires the font to be installed for correct display.

When to convert to outlines?

• Always when exporting final file for print

• Before sending file to printer

• After completing all text corrections (conversion is irreversible)

Keep a copy with active fonts

Always keep a working version of the file with active fonts:

• project_v3_WORKING.ai — with fonts, for further editing

• project_v3_PRINT.ai — with outlines, for production

Minimum text sizes

Text type	Flexography	Rotogravure	Digital
Positive text (dark on light)	6 pt	5 pt	4 pt
Negative text (light on dark)	8 pt	7 pt	5 pt
Single-color text	5 pt	4 pt	4 pt
Multi-color text (CMYK)	8 pt	7 pt	6 pt

Negative text (reversed from background) is harder to print — always use larger size and simpler fonts (sans-serif).

Step 6: Color separation verification

Color separations are a technical aspect of file preparation that determines correct transfer of design to packaging.

What are separations?

Each color in printing is applied separately — CMYK is 4 separate passes through the machine (+ possible spot colors). Separation is the process of dividing the design into these separate color layers.

Most common separation problems

White overprint

White color in CMYK is simply lack of ink — substrate shows through. On white paper this isn't a problem. On film (transparent, metallized) white must be printed as a separate ink (opaque white). Check:

• Does white text/elements on dark background have overprint enabled? (should be DISABLED)

• Is opaque white defined as a separate spot color?

Trapping

Trapping is deliberate overlapping of adjacent colors by 0.1-0.2 mm to avoid white gaps from micro-shifts. In rotogravure and flexography trapping is necessary — in digital printing it's handled automatically.

Minimum line thickness

Element	Flexography	Rotogravure	Digital
Positive line	0.3 pt	0.3 pt	0.25 pt
Negative line	0.5 pt	0.5 pt	0.3 pt
Border	0.4 pt	0.3 pt	0.25 pt

Total Area Coverage (TAC)

Maximum sum of CMYK percentages should not exceed:

• Flexography: 280%
• Rotogravure: 300%
• Digital printing: 320%
• Offset: 300%

Too high TAC causes: ink not drying, smearing, show-through to reverse side, lamination problems.

Step 7: Export to PDF/X-4

The final step is exporting the file in a print standard. PDF/X-4 is currently the recommended standard for packaging.

Why PDF/X-4?

• Supports CMYK, spot colors, and transparencies

• Embeds ICC profiles (color management)

• Ensures compatibility between different prepress systems

• Is a standard accepted by all printers

Export settings in Adobe Illustrator

1. File > Save As > Format: Adobe PDF
2. Adobe PDF Preset: PDF/X-4:2008
3. Marks and Bleeds tab:

   • All Printer's Marks: disabled (printer will add their own)

   • Use Document Bleed Settings: enabled

4. Output tab:

   • Color Conversion: No Conversion

   • Profile Inclusion Policy: Include All Profiles

5. Advanced tab:
   • Overprint: Preserve

Pre-export checklist

Before exporting, go through this list:

• Color space: CMYK (+ spot colors as Spot)

• Image resolution: min. 300 DPI (effective)

• Bleeds: 3-5 mm on each side

• Fonts: converted to outlines

• No RGB elements

• White overprint: disabled

• TAC: below limit for given technology

• Trapping: applied (for flexo/rotogravure)

• Lines: above minimum thickness

• Barcodes: readable, with sufficient quiet zones

• Elements in safety zone (5-8 mm from cut)

• File contains no extra layers/artboards

Most common file preparation mistakes

Based on our prepress experience, here's a ranking of most common mistakes that delay production:

1. RGB colors instead of CMYK

• Problem: file prepared in RGB — colors in print are dull, matte, completely different than on screen.
• Solution: create document in CMYK from the start. Convert photos before import.

2. Low image resolution

• Problem: images downloaded from the internet (72 DPI) look good on screen but in print are blurry and pixelated.
• Solution: use only photos at min. 300 DPI resolution. Check Effective PPI after scaling.

3. Missing bleeds

• Problem: graphic ends exactly at cut line — white strips visible after cutting.
• Solution: extend background and graphics 3-5 mm beyond cut line.

4. Active fonts (not converted to outlines)

• Problem: at printer, font displays differently or is substituted — text is shifted or deformed.
• Solution: Type > Create Outlines (before PDF export).

5. White text with overprint

• Problem: white text on dark background "disappears" — white overprint means lack of ink = visible background.
• Solution: check Overprint Preview and disable overprint for white elements.

6. Text too close to edge

• Problem: important text (product name, legal info) is cut off after packaging cutting.
• Solution: maintain min. 5 mm margin from cut line to key text.

Specific file preparation for different packaging types

Each packaging type has unique technical requirements. Below are the most important differences.

Doypack (stand-up pouch)

• Template includes: front, back, bottom (gusset), sides, seal zone

• Graphics on bottom is visible only when packaging is empty — don't place key information there

• Top seal zone (15-20 mm) — no printing

• If packaging has zipper closure — include its position in design

Flow-pack

• Template is a rectangle with marked fold and seal lines

• Web direction is critical — text must be readable after wrapping

• Longitudinal seal (fin seal) on bottom — don't place graphics there

• Transverse seal on sides — allow 10-15 mm no-print zone

Sleeve (shrink sleeve)

• Template is larger than packaging circumference — film shrinks 40-70%

• Design must account for distortion (stretching) before shrinking

• Printer provides template with distortion grid applied

• Special attention to text and barcodes — cannot be distorted after shrinking

Folding carton

• ArtiosCAD template with crease, cut, and perforation lines

• Glue areas (flaps) — no printing

• Account for folding sequence — which panels are visible, which are covered

• Barcodes always on flat surface, never on fold

Barcodes and regulatory markings

Barcode technical requirements

Barcodes (EAN-13, UPC, QR) are elements that must meet strict standards to be readable by scanners:

• Resolution: min. 600 DPI (ideal: 1200 DPI)
• Quiet zones: min. 3.63 mm on both sides of EAN-13
• Color: best readability is black bars on white background. Avoid red, orange, and yellow background — laser scanners don't read these colors
• Orientation: vertical (ladder) or horizontal (picket fence) — both acceptable, but ladder is preferred on cylindrical packaging
• Scaling: 80-200% of nominal size (100% = 37.29 x 26.26 mm for EAN-13)

Mandatory markings on food packaging

When planning graphic layout, reserve space for legally required information:

• Product name and ingredient list

• Nutritional table

• Net weight

• Minimum durability date / best before

• Storage conditions

• Manufacturer/importer data

• Batch number (LOT)

• Recycling symbols (Green Dot, Mobius Loop, material code)

• Allergens (graphically highlighted — bold, frame)

Design preparation tools

Professional (recommended)

• Adobe Illustrator: industry standard for packaging — full CMYK, spot, and separation support
• Adobe Photoshop: photo editing, retouching, color conversion
• CorelDRAW: alternative to Illustrator, popular in Central Europe
• Esko ArtPro+: specialized prepress software for packaging

Preflight (verification)

• Adobe Acrobat Pro: PDF preflight — checking resolution, colors, fonts
• Enfocus PitStop: advanced preflight and PDF auto-correction
• Esko Automation Engine: automatic verification and correction of packaging files

More information about differences in requirements between printing technologies in our article rotogravure vs digital printing, and about current trends in packaging design in 2026 design trends.

Contact us

Have doubts about file preparation? Send us your design — our prepress department will verify it technically free of charge and prepare a report with any comments. We help at every stage — from technical template to final production file.

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