Printing & Packaging Processes

Separating artwork into CMYK process color, converting RGB files and building optional Pantone spot channels, with ICC-based color management so brand colors remain consistent from screen to press. Included as standard prepress work in every printed project.

Includes: CMYK color separation, RGB to CMYK conversion, Spot color separation, Pantone color matching, ICC color management

Defining separate production layers for white ink, varnish, foil stamping, embossing and spot UV during file preparation, so every finishing effect has a clean, production-ready mask before printing begins.

Includes: White ink layer, Varnish layer, Foil stamping layer, Embossing layer, Spot UV layer

Building accurate dielines with fold, crease, window and glue-flap geometry, plus correct bleed and safe margins, so printed artwork and structural cutting stay perfectly aligned through converting.

Includes: Dieline preparation, Bleed setup

Applying trapping and overprint settings to prevent white hairlines between adjacent ink areas and to control how overlapping colors and effects combine on press.

Includes: Trapping, Overprint settings

Soft proofing for color-accurate on-screen review and digital proofing for a physical contract proof, giving brand owners a reliable approval point before any plates are made.

Includes: Digital proofing, Soft proofing

Computer-to-plate imaging that converts approved digital files into offset printing plates, including thermal CTP for stable imaging and processless CTP options that reduce chemistry and waste.

Includes: CTP plate making, Thermal CTP, Processless CTP

Preparation knowledge for flexographic photopolymer and digitally imaged plates, gravure engraved cylinders and screen printing meshes. These plate routes apply only when the matching press route is selected for a project.

Includes: Photopolymer plates, Digital flexo plates, Engraved cylinders, Screen preparation

Plate-based lithographic printing for medium to large runs, delivering sharp CMYK and Pantone color on paperboard, paper and specialty stocks. ZKPACKS offers offset printing for cartons, cards, tags and bags.

Includes: Offset Printing

Pre-mixed Pantone inks that reproduce brand colors precisely and consistently across the run, ideal for logos, color blocks and packaging where the exact brand hue matters.

Includes: Spot Color / Pantone Printing

Printing with inks cured instantly by ultraviolet light, allowing work on coated and non-absorbent substrates. Ink, coating and substrate compatibility are confirmed with samples during project review.

Includes: UV Printing

LED-UV is an energy-efficient instant-cure UV printing variant that runs cooler and uses less power than conventional UV lamps. Availability depends on the press route selected for the project.

Includes: LED-UV Printing

H-UV and hybrid UV systems cure ink instantly with reduced heat and energy compared with conventional UV. This variant requires dedicated press and ink systems, so it is reviewed per project rather than offered as a standard route.

Includes: H-UV / Hybrid UV

Screen printing deposits thick ink layers for strong whites, textures and specialty effects on flat sheets. Mesh, ink and substrate combinations are confirmed per project when this route is required.

Includes: Screen Printing

Flexographic printing is a roll-fed method suited to labels, films and corrugated board. It is arranged through the production route that best fits the project, with samples confirmed before quotation.

Includes: Flexographic Printing

Gravure printing delivers long-run consistency for high-volume films, foils and flexible packaging. ZKPACKS does not operate gravure presses; this entry is knowledge sharing to help you plan projects that may use a partner route.

Includes: Gravure Printing

Digital printing produces short runs, samples and personalized pieces without conventional plates, with fast turnaround and device-dependent color. It can be included in a project where quantity and variability suit it.

Includes: Digital Printing

Variable data printing personalizes codes, names, serial numbers and QR content within a single run, typically on a digital route. Data file preparation and verification are confirmed during project review.

Includes: Variable Data Printing

Specialty inks add metallic, pearlescent, fluorescent, glow-in-the-dark, thermochromic, photochromic, scented or scratch-off effects. Ink chemistry, substrate compatibility and minimums are confirmed with samples before quotation.

Includes: Metallic ink, Pearlescent ink, Fluorescent ink, Glow-in-the-dark ink, Thermochromic ink, Photochromic ink, Scented ink, Scratch-off ink

UV fluorescent security inks are invisible in normal light and glow under UV, used for anti-counterfeit marks and authentication. They are quoted as a special order with materials and minimums confirmed per project.

Includes: UV fluorescent security ink

Water-based coatings and overprint varnish protect printed surfaces with a clear film, adding gloss, matte or satin sheen while keeping the paper easier to recycle than film lamination.

Includes: Water-Based Coating, Overprint Varnish

A full-surface UV coating cures to a hard, glossy finish that resists scuffing and moisture. Coating chemistry and compatibility with the printed inks are confirmed during project review.

Includes: Full UV Coating

Spot UV applies localized high-gloss coating over selected graphics, while reverse UV (drip-off) creates gloss and matte contrast across one surface. Effect masks are prepared in prepress and results are confirmed with samples.

Includes: Spot UV, Reverse UV / Drip-Off Effect

Dimensional and textured UV variants build raised, 3D, screen-applied, textured, frosted or crystal-clear effects. These require special coating systems and are confirmed with samples before quotation.

Includes: Raised UV, 3D UV, Screen UV, Textured UV, Frosted UV, Crystal UV

Film lamination bonded over the printed sheet in gloss, matte or soft-touch finishes, adding protection, color depth and a premium feel. ZKPACKS offers these as standard finishing options.

Includes: Gloss Lamination, Matte Lamination, Soft-Touch Lamination

Specialty films add velvet, anti-scuff, anti-fingerprint, holographic, metallic, pearlescent or rainbow iridescent surfaces. Film availability and performance are confirmed per project with samples.

Includes: Velvet Lamination, Anti-Scuff Matte Lamination, Anti-Fingerprint Lamination, Holographic Lamination, Metallic Lamination, Pearlescent Lamination, Rainbow / Iridescent Film

Hot foil stamping presses metallic, holographic or pigmented foil into the surface with a heated die, producing crisp, premium accents. Dies are required and the effect is confirmed with samples during project review.

Includes: Hot Foil Stamping

Cold foil printing applies metallic foil through adhesive printed in the same pass, supporting fine gradients and large metallic areas. Foil and adhesive compatibility with the press route are confirmed per project.

Includes: Cold Foil Printing

Digital foil printing applies metallic or colored foil finishes without conventional stamping dies, supporting short runs and variable foil placement. It requires dedicated digital foil equipment and is reviewed per project.

Includes: Digital Foil

Embossing raises artwork above the surface and debossing presses it in, adding tactile relief that works beautifully with foil and uncoated paper. ZKPACKS offers both as standard finishing options.

Includes: Embossing, Debossing

Multi-level, sculptured and textured embossing create layered relief and surface grain that standard embossing cannot. These require custom tooling and are confirmed with samples before quotation.

Includes: Multi-Level Embossing, Sculptured Embossing, Texture Embossing

Frosted, pearlescent, metallic and holographic effects add light-play and depth to a printed surface, typically through specialty films, coatings or foils. The most suitable route and samples are confirmed per project.

Includes: Frosted Effect, Pearlescent Effect, Metallic Effect, Holographic Effects

Specialty touch and texture treatments combine coatings, films, inks and embossing to create a custom tactile experience. The combination is designed per project and validated with physical samples.

Includes: Specialty Touch & Texture

Specialty visual effects cover combinations of foils, UV, effects films and specialty inks that create a distinctive shelf presence. Each combination is reviewed and sampled per project.

Includes: Specialty Visual Effects

Security and smart packaging effects go beyond surface decoration: NFC and RFID tags, sensors and connected labels are a separate smart packaging capability requiring chip sourcing, antenna design and testing, not just a surface finish. ZKPACKS shares this knowledge to help you plan, with any implementation handled as a dedicated project rather than a standard surface effect.

Includes: Security & Smart Packaging Effects

Flatbed die cutting stamps custom shapes from sheets with a steel-rule die, while rotary die cutting serves high-volume roll-fed work. ZKPACKS offers die cutting as a standard converting step for cartons, cards and tags.

Includes: Flatbed die cutting, Rotary die cutting

Laser and digital cutting shape parts without steel-rule tooling, suiting prototypes, short runs and intricate detail. Machine availability and cost per piece are confirmed during project review.

Includes: Laser cutting, Digital cutting

Creases and scores create clean fold lines that prevent board cracking on thick or coated stocks, including reverse creases for inside folds and double creases for heavy board.

Includes: Standard crease, Reverse crease, Double crease

Kiss cutting cuts through a top layer without cutting the backing, used for labels, stickers and adhesive sheets. It can be included where the product calls for it, with samples confirmed during review.

Includes: Kiss cutting

Window cutting removes an opening in the panel and window patching applies a clear film over it, letting customers see the product. Film grade and window shape are confirmed per project.

Includes: Window cutting, Window patching

Mounting bonds printed sheets onto paper, board or corrugated board, including sheet-to-sheet mounting for rigid components and corrugated lamination for strength. Board combinations are confirmed with samples.

Includes: Paper mounting, Board mounting, Sheet-to-sheet mounting, Corrugated lamination

E, F, B, C, EB and BC flutes offer different thicknesses and crush strength for mailers, display boxes and protective structures. Flute selection depends on the project's weight and stacking requirements.

Includes: E flute, F flute, B flute, C flute, EB flute, BC flute

Folding shapes printed sheets into cartons, sleeves, folders and mailers, with machine folding for volume and hand folding for complex, multi-panel or accordion structures.

Includes: Machine folding, Hand folding, Multi-panel folding, Accordion folding

Gluing joins carton panels into final form, including straight-line, lock-bottom and auto-bottom styles, plus 4-corner and 6-corner box construction for stronger, more complex structures.

Includes: Straight-line gluing, Lock-bottom gluing, Auto-bottom, 4-corner box, 6-corner box, Automatic gluing

Rigid box assembly combines greyboard cutting, V-grooving, corner taping, box forming, wrapping and edge turning to build durable lid-and-base boxes. Tooling and assembly steps are confirmed per project.

Includes: Hand assembly, Greyboard cutting, V-grooving, Corner taping, Box forming, Wrapping, Edge turning

Inserts hold products securely using paperboard, EVA, flocked EVA, PU foam, EPE or XPE structures. PVC remains available only as a traditional option and is not recommended for new projects.

Includes: Paper Inserts, EVA, Flocked EVA, PU foam, EPE, XPE

PET, RPET and PP trays are thermoformed plastic inserts that add crush protection and a clean presentation. Trays are sourced to specification, and recyclable RPET is preferred where suitable.

Includes: PET tray, RPET tray, PP tray

Molded pulp, recycled paper pulp, bagasse and bamboo fiber options provide renewable insert and tray structures. Availability and any recyclable, compostable or bio-based claims are subject to material specification and supplier documentation.

Includes: Molded pulp, Recycled paper pulp, Bagasse, Bamboo fiber options

Booklet and manual binding includes saddle stitching, perfect binding, PUR binding, thread sewing, case binding and spiral binding for instruction books and product literature. The binding route is confirmed per project.

Includes: Saddle stitching, Perfect binding, PUR binding, Thread sewing, Case binding, Spiral binding